Metal part manufacturing device, metal part manufacturing method, and motor manufacturing method

Abstract

To provide a metal component manufacturing device which can prevent cracks that occur in a metal workpiece from forming deeper than a tip of a punch, can control a shape of a deep groove formed in the metal workpiece while splitting the metal workpiece by use of the punch.SOLUTION: A metal component manufacturing device 1 comprises a first punch 10 including a first tip 13, and a guide member 20 which is so located as to face a metal workpiece 40 with a space therebetween. By splitting the metal workpiece 40 into a first metal portion 46 and a first metal piece 47 by use of the first punch 10, a deep groove 48 is formed. The guide member 20 contacts the first metal piece 47, and guides the first metal piece 47.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present disclosure relates to a metal part manufacturing apparatus, a metal part manufacturing method, and a motor manufacturing method. [Background technology]

[0002] Japanese Patent Laid-Open Publication No. 2016-124084 (Patent Document 1) discloses a method for processing the end of a metal pipe. The processing method disclosed in Patent Document 1 includes a first step of moving a presser die that fixes the metal pipe in the longitudinal direction of the metal pipe, and a second step of splitting the end of the metal pipe using a splitting punch by moving the splitting punch in the longitudinal direction of the metal pipe to a depth corresponding to the tip of the presser die. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2016-124084 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the processing method disclosed in Patent Document 1, the metal piece split from the metal tube in the second step warps significantly, making it impossible to control the shape of the deep groove. The present disclosure has been made in consideration of the above-mentioned problems, and an object of a first aspect of the present disclosure is to provide a metal part manufacturing apparatus and a metal part manufacturing method that can prevent cracks from occurring in a metal workpiece from occurring deeper than the tip of the punch and can control the shape of the deep groove formed in the metal workpiece while splitting the metal workpiece using the punch. An object of a second aspect of the present disclosure is to provide a motor manufacturing method that uses a metal part manufactured using the metal part manufacturing method disclosed herein. [Means for solving the problem]

[0005] The metal part manufacturing apparatus of the present disclosure includes a first punch including a first tip and a guide member arranged opposite a first portion of a metal workpiece with a gap therebetween. The metal workpiece includes an end face, and the first portion of the metal workpiece also includes the end face. While the first tip of the first punch is moved from the end face of the metal workpiece to the interior of the metal workpiece, the first portion of the metal workpiece is split into a first metal portion and a first metal piece, thereby forming a deep groove on the end face of the metal workpiece, and the deep groove is formed between the first metal portion and the first metal piece. While the first tip of the first punch is moved from the end face of the metal workpiece to the interior of the metal workpiece, the guide member contacts and guides the first metal piece.

[0006] The method for manufacturing a metal part of the present disclosure includes disposing a guide member opposite a first portion of a metal workpiece with a gap therebetween. The metal workpiece includes an end face. The first portion of the metal workpiece includes the end face. The method for manufacturing a metal part of the present disclosure includes forming a deep groove in the end face of the metal workpiece using a first punch including a first tip. Forming the deep groove includes splitting the first portion of the metal workpiece into a first metal portion and a first metal piece while moving the first tip of the first punch from the end face of the metal workpiece to the interior of the metal workpiece. The deep groove is formed between the first metal portion and the first metal piece. The method for manufacturing a metal part of the present disclosure includes contacting the first metal piece with the guide member and guiding the first metal piece with the guide member while moving the first tip of the first punch from the end face of the metal workpiece to the interior of the metal workpiece.

[0007] The motor manufacturing method of the present disclosure includes forming a stator frame using the metal part manufacturing method of the present disclosure, placing a stator core within the stator frame, and assembling a rotor including a rotor core facing the stator core within the stator frame. [Effects of the Invention]

[0008] In the metal part manufacturing apparatus and metal part manufacturing method disclosed herein, the first metal piece is deformed by the guide member. Therefore, it is possible to control the shape of the deep groove formed in the metal workpiece while using the first punch to split the metal workpiece. Furthermore, in the metal part manufacturing apparatus and metal part manufacturing method disclosed herein, when the first metal piece is deformed by the guide member, the first metal piece experiences deformation resistance from the guide member. Due to this deformation resistance, a portion of the metal material constituting the metal workpiece accumulates in a portion of the metal workpiece facing the first tip of the first punch. Therefore, it is possible to prevent cracks that occur in the metal workpiece from occurring deeper than the first tip of the first punch.

[0009] According to the motor manufacturing method of the present disclosure, a motor having a stator frame in which deep grooves with controlled shapes are formed can be obtained. [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a block diagram of a metal part manufacturing apparatus according to a first embodiment. [Figure 2] 2 is a schematic cross-sectional view of a first punch included in the metal part manufacturing apparatus of the first embodiment, taken along a cross section perpendicular to the axial direction of the first punch. FIG. [Figure 3] 2 is a schematic cross-sectional view of a first punch included in the metal part manufacturing apparatus of the first embodiment, taken along the axial direction of the first punch. FIG. [Figure 4] 4 is a schematic, partially enlarged cross-sectional view of a first punch included in the metal part manufacturing apparatus according to the first embodiment, showing a region IV shown in FIG. 3. FIG. [Figure 5] 1 is a schematic cross-sectional view showing one step of a method for manufacturing a metal part according to a first embodiment. [Figure 6] 6 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 5 in the method for manufacturing a metal part according to the first embodiment. [Figure 7] 7 is a schematic, partially enlarged cross-sectional view of the step shown in FIG. 6 in the method for manufacturing the metal part according to the first embodiment. [Figure 8]8 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 7 in the method for manufacturing a metal component according to the first embodiment. [Figure 9] FIG. 10 is a schematic cross-sectional view showing one step of a method for manufacturing a metal part according to a second embodiment. [Figure 10] 10 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 9 in the method for manufacturing a metal component according to the second embodiment. [Figure 11] FIG. 10 is a schematic cross-sectional view showing one step of a method for manufacturing a metal part according to a third embodiment. [Figure 12] 12 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 11 in the method for manufacturing a metal part according to the third embodiment. FIG. [Figure 13] FIG. 10 is a schematic cross-sectional view showing one step of a method for manufacturing a metal part according to a fourth embodiment. [Figure 14] 14 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 13 in the method for manufacturing a metal component according to a fourth embodiment. [Figure 15] FIG. 10 is a schematic cross-sectional view showing one step of a method for manufacturing a metal part according to a fifth embodiment. [Figure 16] 16 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 15 in the method for manufacturing a metal part according to the fifth embodiment. FIG. [Figure 17] FIG. 13 is a schematic cross-sectional view showing one step of a method for manufacturing a metal part according to a sixth embodiment. [Figure 18] 18 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 17 in the method for manufacturing a metal part according to the sixth embodiment. FIG. [Figure 19] FIG. 13 is a schematic cross-sectional view showing one step of a method for manufacturing a metal part according to a seventh embodiment. [Figure 20] 20 is a schematic, partially enlarged cross-sectional view of the step shown in FIG. 19 in the method for manufacturing a metal part according to a seventh embodiment. FIG. [Figure 21] 20 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 19 in the method for manufacturing a metal part according to the seventh embodiment. FIG. [Figure 22] FIG. 13 is a schematic cross-sectional view showing one step of a method for manufacturing a metal part according to an eighth embodiment. [Figure 23]23 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 22 in the method for manufacturing a metal part according to the eighth embodiment. FIG. [Figure 24] 24 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 23 in the method for manufacturing a metal part according to the eighth embodiment. FIG. [Figure 25] 25 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 24 in the method for manufacturing a metal part according to the eighth embodiment. FIG. [Figure 26] FIG. 13 is a schematic cross-sectional view showing one step of a method for manufacturing a metal part according to a ninth embodiment. [Figure 27] 27 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 26 in the method for manufacturing a metal part according to a ninth embodiment. FIG. [Figure 28] 28 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 27 in the method for manufacturing a metal part according to a ninth embodiment. [Figure 29] 29 is a schematic, partially enlarged cross-sectional view of the step shown in FIG. 28 in the method for manufacturing a metal part according to a ninth embodiment. [Figure 30] 29 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 28 in the method for manufacturing a metal part according to a ninth embodiment. FIG. [Figure 31] 31 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 30 in the method for manufacturing a metal part according to a ninth embodiment. [Figure 32] 20 is a schematic cross-sectional view of a first punch included in a metal part manufacturing apparatus according to a tenth embodiment, taken along the axial direction of the first punch. FIG. [Figure 33] FIG. 33 is a schematic, partially enlarged cross-sectional view of a region XXXII shown in FIG. 32 of a first punch included in the metal part manufacturing apparatus according to the tenth embodiment. [Figure 34] FIG. 20 is a schematic, partially enlarged cross-sectional view showing one step of a method for manufacturing a metal part according to a tenth embodiment. [Figure 35] FIG. 22 is a schematic cross-sectional view of a metal part according to an eleventh embodiment. [Figure 36] FIG. 23 is a schematic cross-sectional view of a metal part according to a modified example of the eleventh embodiment. [Figure 37] FIG. 22 is a schematic cross-sectional view showing one step of a method for manufacturing a metal part according to a twelfth embodiment. [Figure 38] 38 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 37 in the method for manufacturing a metal part according to a twelfth embodiment. FIG. [Figure 39] FIG. 22 is a schematic cross-sectional view of a metal part according to a twelfth embodiment. [Figure 40] FIG. 22 is a schematic cross-sectional view showing one step of a method for manufacturing a metal part according to a thirteenth embodiment. [Figure 41] 41 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 40 in the method for manufacturing a metal part according to a thirteenth embodiment. FIG. [Figure 42] 42 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 41 in the method for manufacturing a metal part according to a thirteenth embodiment, and is also a schematic cross-sectional view of the metal part according to the thirteenth embodiment. FIG. [Figure 43] FIG. 22 is a schematic cross-sectional view showing one step of a method for manufacturing a metal part according to a fourteenth embodiment. [Figure 44] 44 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 43 in the method for manufacturing a metal part according to a fourteenth embodiment. FIG. [Figure 45] 45 is a schematic cross-sectional view showing a step subsequent to the step shown in FIG. 44 in the method for manufacturing a metal part according to a fourteenth embodiment, and is also a schematic cross-sectional view of the metal part according to the fourteenth embodiment. [Figure 46] FIG. 22 is a schematic cross-sectional view of a metal part according to a fifteenth embodiment. [Figure 47] FIG. 23 is a schematic cross-sectional view of a metal part according to a modified example of the fifteenth embodiment. [Figure 48] FIG. 22 is a schematic cross-sectional view of a motor according to a sixteenth embodiment. [Figure 49] FIG. 23 is a flowchart showing a method for manufacturing a motor according to a sixteenth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, embodiments of the present disclosure will be described. Note that the same reference numerals are used to designate the same components, and the description thereof will not be repeated.

[0012] Embodiment 1

[0013] A metal part manufacturing apparatus 1 according to a first embodiment will be described with reference to Figures 1 to 8. The metal part manufacturing apparatus 1 processes a metal workpiece 40 (see Figures 5 to 8) to manufacture a metal part 2 (see Figure 8) from the metal workpiece 40.

[0014] As shown in FIGS. 5 to 8 , in this embodiment, the metal workpiece 40 is a hollow metal workpiece, such as a metal tube 40a. In this embodiment, the cross-sectional shape of the metal tube 40a in a cross section perpendicular to the longitudinal direction (axial direction) of the metal tube 40a is circular. The metal workpiece 40 is not particularly limited, but may be formed of, for example, copper, aluminum, iron, a copper alloy, an aluminum alloy, or an iron alloy. The metal tube 40a includes an outer surface 41, an inner surface 42, and an end surface 43. The end surface 43 is connected to the outer surface 41 and the inner surface 42. The longitudinal direction of the metal tube 40a is the z direction. The end surface 43 extends along the x direction perpendicular to the z direction and the y direction perpendicular to the z direction and the x direction.

[0015] 1 to 8, metal part manufacturing apparatus 1 includes a first punch 10, a guide member 20, and a fixing member 30. Metal part manufacturing apparatus 1 may further include a controller 29.

[0016] 5 to 8, the fixing member 30 fixes the metal workpiece 40. The fixing member 30 is, for example, a solid fixing member. For example, the fixing member 30 is fitted into a hole of a metal tube 40a defined by an inner surface 42. The fixing member 30 is in contact with the inner surface 42.

[0017] As shown in Figures 2 to 4, the first punch 10 is a hollow punch. The axial direction (longitudinal direction) of the first punch 10 is the z-direction. As shown in Figures 5 to 8, the first punch 10 is used to process (e.g., press-form) the metal workpiece 40 by moving the first punch 10 in the axial direction (z-direction) of the first punch 10 relative to the metal workpiece 40. The cross-sectional shape of the first punch 10 shown in Figure 2 is the same as the cross-sectional shape of the metal workpiece 40, and is, for example, circular. The cross-sectional shape of the first punch 10 is the shape of the punch in a cross section (xy plane) perpendicular to the movement direction (z-direction) of the first punch 10. The cross-sectional shape of the metal workpiece 40 is the shape of the metal workpiece 40 in a cross section perpendicular to the movement direction of the first punch 10.

[0018] The first punch 10 includes an outer surface 11, an inner surface 12, a rounded first tip 13, and a first inclined surface 14. The outer surface 11 and the inner surface 12 each extend in the axial direction (z direction) of the first punch 10. In a cross section along the axial direction (z direction) of the first punch 10, the outer surface 11 and the inner surface 12 each are straight lines extending in the axial direction of the first punch 10.

[0019] The rounded first tip 13 is connected to the inner surface 12 and the first inclined surface 14. The first inclined surface 14 is connected to the rounded first tip 13 and the outer surface 11. The first inclined surface 14 is inclined so as to move away from the inner surface 12 as it moves away from the rounded first tip 13. As shown in Figures 5 to 8, the first inclined surface 14 is inclined so as to move away from the metal workpiece 40 as it moves away from the rounded first tip 13. In a cross section along the axial direction (z direction) of the first punch 10, the first inclined surface 14 is an inclined straight line inclined with respect to the axial direction of the first punch 10.

[0020] As shown in FIGS. 5 to 7 , the first tip 13 of the first punch 10 is moved from the end face 43 of the metal workpiece 40 toward the interior of the metal workpiece 40, splitting the first portion of the metal workpiece 40 into a first metal portion 46 and a first metal piece 47. In a cross section along the axial direction (z direction) of the first punch 10, the inner surface 12 is a straight line extending in the axial direction of the first punch 10, while the first inclined surface 14 is a straight line inclined relative to the axial direction of the first punch 10. Therefore, the first metal piece 47 is formed only on the outer surface 41 of the metal tube 40a. The outer surface of the first metal portion 46 extends in the axial direction of the first punch 10. In a cross section along the axial direction of the first punch 10, the outer surface of the first metal portion 46 is a straight line extending in the axial direction of the first punch 10. The first inclined surface 14 guides the first metal piece 47 toward the guide member 20.

[0021] 5 to 7, the guide member 20 is disposed opposite the first portion of the metal workpiece 40 with a gap G therebetween. The gap G is larger than the thickness T1 of the first punch 10. For example, the gap G is larger than the thickness T1 of the first punch 10 by 10% or more of the thickness t of the first metal piece 47.

[0022] In this embodiment, the guide member 20 is a hollow guide member. The inner surface of the guide member 20 functions as a guide surface for the first metal piece 47. In this embodiment, the gap G is the gap between the outer surface 41 of the metal tube 40a and the inner surface of the guide member 20. The inner surface of the guide member 20 extends in the axial direction (z direction) of the first punch 10. In a cross section along the axial direction of the first punch 10, the inner surface of the guide member 20 is a straight line extending in the axial direction of the first punch 10. The cross-sectional shape of the guide member 20 is the same as the cross-sectional shape of the metal workpiece 40, and is, for example, circular. The cross-sectional shape of the guide member 20 is the shape of the guide member 20 in a cross section (xy plane) perpendicular to the movement direction (z direction) of the first punch 10. While the first punch 10 is moved relative to the metal workpiece 40 to process the metal workpiece 40, the guide member 20 does not move relative to the metal workpiece 40, and the position of the guide member 20 relative to the metal workpiece 40 is maintained.

[0023] As shown in FIGS. 6 and 7 , while the first tip 13 of the first punch 10 is moving from the end surface 43 of the metal workpiece 40 to the interior of the metal workpiece 40, the guide member 20 contacts and guides the first metal piece 47. The first metal piece 47 is deformed by the guide member 20 into a metal piece extending along the axial direction (z-direction) of the first punch 10. The first metal piece 47 deformed by the guide member 20 extends, for example, parallel to the outer surface of the first metal portion 46. Thus, as shown in FIG. 8 , a deep groove 48 is formed on the end surface 43 of the metal workpiece 40. The deep groove 48 is formed between the first metal portion 46 and the first metal piece 47. The depth direction of the deep groove 48 is the axial direction (z-direction) of the metal workpiece 40 or the longitudinal direction (z-direction) of the metal workpiece 40. The width direction of the deep groove 48 is the radial direction of the metal workpiece 40. In this specification, the deep groove 48 means a groove having a depth of 1 mm or more. In this embodiment, the deep groove 48 is formed in the outer peripheral region of the end face 43 of the metal workpiece 40 in the radial direction.

[0024] The controller 29 controls the first punch 10. For example, the controller 29 moves the first punch 10 in its axial direction (z direction) to machine the metal workpiece 40 using the first punch 10 (see FIGS. 5 to 7 ), or moves the first punch 10 away from the metal workpiece 40 (see FIG. 8 ). The controller 29 may further control the fixing member 30, the guide member 20, or both the fixing member 30 and the guide member 20. For example, the controller 29 moves the fixing member 30 in the axial direction of the first punch 10 to fit it into the hole of the metal tube 40a. For example, the controller 29 moves the guide member 20 in the axial direction of the first punch 10 to position the guide member 20 facing the first portion of the metal workpiece 40 with a gap G therebetween.

[0025] Referring to FIG. 1 , the controller 29 is, for example, a microcomputer including a processor and a storage device such as a RAM (Random Access Memory) and a ROM (Read Only Memory). The processor may be, for example, a CPU (Central Processing Unit). The RAM functions as a working memory that temporarily stores data processed by the processor. The storage device stores, for example, programs to be executed by the processor. In this embodiment, the processor executes the programs stored in the storage device, causing the controller 29 to control the first punch 10 and the like. Instead of a microcomputer, an FPGA (Field-Programmable Gate Array) may be used as the controller 29. The various processes in the controller 29 are not limited to being executed by software, but may also be executed by dedicated hardware (electronic circuits).

[0026] 5 to 8, a method for manufacturing a metal component 2 according to this embodiment using the metal component manufacturing apparatus 1 will be described. The metal component 2 according to this embodiment is a metal tube 40a having a deep groove 48 formed in an outer peripheral region of an end face 43 in the radial direction of the metal tube 40a.

[0027] 5, the metal workpiece 40 is fixed using the fixing member 30. For example, the fixing member 30 is fitted into a hole in the metal tube 40a defined by the inner surface 42. The fixing member 30 contacts the inner surface 42 to fix a first portion of the metal workpiece 40. The first portion of the metal workpiece 40 includes an end surface 43.

[0028] 5, the guide member 20 is disposed opposite the first portion of the metal workpiece 40 with a gap G therebetween. The guide member 20 is disposed opposite the outer surface 41 of the metal pipe 40a with a gap therebetween.

[0029] As shown in FIGS. 5 to 7 , a deep groove 48 is formed in the end surface 43 of a metal workpiece 40 using a first punch 10 including a rounded first tip 13. Forming the deep groove 48 involves splitting a first portion of the metal workpiece 40 into a first metal portion 46 and a first metal piece 47 while moving the first tip 13 of the first punch 10 from the end surface 43 of the metal workpiece 40 toward the interior of the metal workpiece 40. In a cross section along the axial direction (z direction) of the first punch 10, the inner surface 12 of the first punch 10 is a straight line extending in the axial direction of the first punch 10, while the first inclined surface 14 of the first punch 10 is a straight line inclined relative to the axial direction of the first punch 10. Therefore, the first metal piece 47 is formed only in the outer surface 41 of the metal tube 40a. The deep groove 48 is formed between the first metal portion 46 and the first metal piece 47.

[0030] 6 and 7, the first inclined surface 14 of the first punch 10 guides the first metal piece 47 toward the guide member 20. The first inclined surface 14 is connected to the first tip 13 of the first punch 10, and is inclined so as to move away from the metal workpiece 40 as it moves away from the first tip 13.

[0031] 6 and 7 , while the first tip 13 of the first punch 10 is moved from the end face 43 of the metal workpiece 40 toward the inside of the metal workpiece 40, the first metal piece 47 is brought into contact with the guide member 20 and guided by the guide member 20. The first metal piece 47 is deformed by the guide member 20 into a metal piece extending along the axial direction (z direction) of the first punch 10. The first metal piece 47 deformed by the guide member 20 extends, for example, parallel to the outer surface of the first metal portion 46. While the first punch 10 is moved relative to the metal workpiece 40 to process the metal workpiece 40, the guide member 20 does not move relative to the metal workpiece 40, and the position of the guide member 20 relative to the metal workpiece 40 is maintained.

[0032] 8, the first punch 10 is moved away from the metal workpiece 40. In this way, the metal part 2 is obtained.

[0033] (action)

[0034] While the first tip 13 of the first punch 10 is being moved from the end face 43 of the metal workpiece 40 to the inside of the metal workpiece 40, the first metal piece 47 comes into contact with the guide member 20 and is guided by the guide member 20. The first metal piece 47 is deformed by the guide member 20 to become a metal piece extending along the axial direction (z direction) of the first punch 10. Therefore, the shape of the deep groove 48 formed in the metal workpiece 40 can be controlled while the metal workpiece 40 is being split using the first punch 10.

[0035] When the first metal piece 47 is deformed by the guide member 20, the first metal piece 47 experiences deformation resistance from the guide member 20. Due to this deformation resistance, a portion of the metal material constituting the metal workpiece 40 accumulates in a portion 40f (see FIG. 7) of the metal workpiece 40 facing the first tip 13. This makes it possible to prevent cracks that occur in the metal workpiece 40 from developing deeper than the first tip 13 of the first punch 10. In addition, the first tip 13 of the first punch 10 is rounded. Therefore, when the metal workpiece 40 is machined using the first punch 10, the concentration of the load applied to the metal workpiece 40 at the first tip 13 of the first punch 10 is alleviated. This makes it possible to prevent cracks that occur in the metal workpiece 40 from developing deeper than the first tip 13 of the first punch 10.

[0036] The smaller the gap G, the greater the deformation resistance that the first metal piece 47 receives from the guide member 20, and more metal material accumulates in the portion 40f of the metal workpiece 40 facing the first tip 13 (see FIG. 7). Therefore, the smaller the gap G, the more effectively cracks that occur in the metal workpiece 40 can be prevented from developing deeper than the first tip 13 of the first punch 10. However, as the deformation resistance that the first metal piece 47 receives from the guide member 20 increases, the load that the first punch 10 receives when processing the metal workpiece 40 increases. Therefore, the first punch 10 may be damaged or worn when processing the metal workpiece 40. In order to reduce damage or wear of the first punch 10 when processing the metal workpiece 40, it is preferable that the gap G be greater than the thickness T1 of the first punch 10 by 10% or more of the thickness t of the first metal piece 47.

[0037] While the first punch 10 is moved relative to the metal workpiece 40 to machine the metal workpiece 40, the guide member 20 does not move relative to the metal workpiece 40, and the position of the guide member 20 relative to the metal workpiece 40 is maintained. Therefore, the depth of the deep groove 48 can be controlled simply by managing the amount of movement of the first punch 10, without using a mold with a complex shape. This increases the degree of freedom in the shape of the metal workpiece 40 and the degree of freedom in the machining direction of the metal workpiece 40.

[0038] (Variation)

[0039] The first tip 13 of the first punch 10 does not have to be rounded. The cross-sectional shape of the metal tube 40a in a cross section perpendicular to the longitudinal direction (axial direction, z direction) of the metal tube 40a is not limited to a circle, and may be, for example, an ellipse or a polygon.

[0040] The cross-sectional shape of the first punch 10 in a cross section (xy plane) perpendicular to the moving direction (z direction) of the first punch 10 is not limited to a circle as shown in Fig. 2, but may be an ellipse or a polygon. The cross-sectional shape of the first punch 10 may be the same as the cross-sectional shape of the metal tube 40a, or may be partially the same as the cross-sectional shape of the metal tube 40a.

[0041] A part of the outer circumferential region of the end face 43 of the metal pipe 40a may be split using the first punch 10. A plurality of locations in the outer circumferential region of the end face 43 of the metal pipe 40a may be split using the first punch 10. When a plurality of locations in the outer circumferential region of the end face 43 of the metal pipe 40a are split, the depths of the plurality of deep grooves 48 corresponding to the plurality of locations may be the same as or different from each other.

[0042] In order to prevent damage and wear to the rounded first tip 13 of the first punch 10, lubricating oil may be supplied to the metal workpiece 40 and the first punch 10 when the metal workpiece 40 is split using the first punch 10.

[0043] The effects of the metal part manufacturing apparatus 1 and the method for manufacturing the metal part 2 according to this embodiment will be described.

[0044] The metal part manufacturing apparatus 1 of this embodiment includes a first punch 10 including a first tip 13 and a guide member 20 arranged opposite a first portion of a metal workpiece 40 with a gap G therebetween. The metal workpiece 40 includes an end face 43, and the first portion of the metal workpiece 40 also includes the end face 43. While the first tip 13 of the first punch 10 is moved from the end face 43 of the metal workpiece 40 toward the interior of the metal workpiece 40, the first portion of the metal workpiece 40 is split into a first metal portion 46 and a first metal piece 47, thereby forming a deep groove 48 in the end face 43 of the metal workpiece 40. The deep groove 48 is formed between the first metal portion 46 and the first metal piece 47. While the first tip 13 of the first punch 10 is moved from the end face 43 of the metal workpiece 40 toward the interior of the metal workpiece 40, the guide member 20 contacts and guides the first metal piece 47.

[0045] Therefore, the first metal piece 47 is deformed by the guide member 20. The shape of the deep groove 48 formed in the metal workpiece 40 can be controlled while the metal workpiece 40 is split using the first punch 10. Furthermore, when the first metal piece 47 is deformed by the guide member 20, the first metal piece 47 receives deformation resistance from the guide member 20. Due to this deformation resistance, a portion of the metal material that constitutes the metal workpiece 40 accumulates in a portion 40f (see FIG. 7) of the metal workpiece 40 that faces the first tip 13. Therefore, it is possible to prevent cracks that occur in the metal workpiece 40 from occurring deeper than the first tip 13 of the first punch 10.

[0046] In the metal part manufacturing apparatus 1 of the present embodiment, the first tip 13 of the first punch 10 is a rounded tip.

[0047] This reduces the concentration of the load applied to the metal workpiece 40 at the first tip 13 of the first punch 10. This prevents cracks from occurring in the metal workpiece 40 deeper than the first tip 13 of the first punch 10.

[0048] In the metal part manufacturing apparatus 1 of this embodiment, the first punch 10 is connected to the first tip 13 and includes a first inclined surface 14 that is inclined so as to move away from the metal workpiece 40 as it moves away from the first tip 13. The first inclined surface 14 guides the first metal piece 47 toward the guide member 20.

[0049] Therefore, the first metal piece 47 is guided more smoothly and reliably toward the guide member 20. The first metal piece 47 is deformed by the guide member 20. The shape of the deep groove 48 formed in the metal workpiece 40 can be controlled. In addition, the first metal piece 47 receives deformation resistance from the guide member 20. Due to this deformation resistance, part of the metal material that makes up the metal workpiece 40 accumulates in a portion 40f (see FIG. 7) of the metal workpiece 40 that faces the first tip 13. It is possible to prevent cracks that occur in the metal workpiece 40 from occurring deeper than the first tip 13 of the first punch 10.

[0050] In the metal part manufacturing apparatus 1 of the present embodiment, the cross-sectional shape of the first punch 10 and the cross-sectional shape of the guide member 20 are the same as the cross-sectional shape of the metal workpiece 40, or are partially the same.

[0051] As such, grooves 48 having various shapes or patterns can be formed in the metal workpiece 40 .

[0052] The metal part manufacturing apparatus 1 of this embodiment further includes a fixing member 30 for fixing the metal workpiece 40.

[0053] Therefore, the deep grooves 48 can be formed in the metal workpiece 40 with higher precision.

[0054] The manufacturing method for the metal part 2 of this embodiment includes disposing a guide member 20 opposite a first portion of the metal workpiece 40 with a gap G therebetween. The metal workpiece 40 includes an end face 43. The first portion of the metal workpiece 40 includes the end face 43. The manufacturing method for the metal part 2 of this embodiment includes forming a deep groove 48 in the end face 43 of the metal workpiece 40 using a first punch 10 including a first tip 13. Forming the deep groove 48 includes splitting the first portion of the metal workpiece 40 into a first metal portion 46 and a first metal piece 47 while moving the first tip 13 of the first punch 10 from the end face 43 of the metal workpiece 40 toward the interior of the metal workpiece 40. The deep groove 48 is formed between the first metal portion 46 and the first metal piece 47. The manufacturing method of the metal part 2 in this embodiment includes bringing the first metal piece 47 into contact with the guide member 20 and guiding the first metal piece 47 with the guide member 20 while moving the first tip 13 of the first punch 10 from the end face 43 of the metal workpiece 40 into the interior of the metal workpiece 40.

[0055] Therefore, the first metal piece 47 is deformed by the guide member 20. The shape of the deep groove 48 formed in the metal workpiece 40 can be controlled while the metal workpiece 40 is split using the first punch 10. Furthermore, when the first metal piece 47 is deformed by the guide member 20, the first metal piece 47 receives deformation resistance from the guide member 20. Due to this deformation resistance, a portion of the metal material that constitutes the metal workpiece 40 accumulates in a portion 40f (see FIG. 7) of the metal workpiece 40 that faces the first tip 13. Therefore, it is possible to prevent cracks that occur in the metal workpiece 40 from occurring deeper than the first tip 13 of the first punch 10.

[0056] In the method for manufacturing the metal part 2 of this embodiment, the first tip 13 of the first punch 10 is a rounded tip.

[0057] This reduces the concentration of the load applied to the metal workpiece 40 at the first tip 13 of the first punch 10. This prevents cracks from occurring in the metal workpiece 40 deeper than the first tip 13 of the first punch 10.

[0058] The method for manufacturing a metal part 2 in this embodiment further includes guiding the first metal piece 47 toward the guide member 20 by the first inclined surface 14 of the first punch 10. The first inclined surface 14 is connected to the first tip 13 of the first punch 10, and is inclined so as to move away from the metal workpiece 40 as it moves away from the first tip 13.

[0059] Therefore, the first metal piece 47 is guided more smoothly and reliably toward the guide member 20. The first metal piece 47 is deformed by the guide member 20. The shape of the deep groove 48 formed in the metal workpiece 40 can be controlled. In addition, the first metal piece 47 receives deformation resistance from the guide member 20. Due to this deformation resistance, part of the metal material that makes up the metal workpiece 40 accumulates in a portion 40f (see FIG. 7) of the metal workpiece 40 that faces the first tip 13. It is possible to prevent cracks that occur in the metal workpiece 40 from occurring deeper than the first tip 13 of the first punch 10.

[0060] In the method for manufacturing the metal part 2 of this embodiment, the cross-sectional shape of the first punch 10 and the cross-sectional shape of the guide member 20 are the same as or partially the same as the cross-sectional shape of the metal workpiece 40, respectively.

[0061] As such, grooves 48 having various shapes or patterns can be formed in the metal workpiece 40 .

[0062] Embodiment 2

[0063] 9 and 10, a method for manufacturing a metal part 2b according to the second embodiment using the metal part manufacturing apparatus 1 will be described. The method for manufacturing a metal part 2b according to the second embodiment includes the same steps as the method for manufacturing a metal part 2 according to the first embodiment, and achieves the same effects as the method for manufacturing a metal part 2 according to the first embodiment, but differs from the method for manufacturing a metal part 2 according to the first embodiment in the following respects.

[0064] In this embodiment, the metal workpiece 40 is a hollow metal workpiece, and the hollow metal workpiece is, for example, a drawn product 40b drawn from a metal plate. The drawn product 40b includes a bottom plate 51 and a side wall 52 connected to the bottom plate 51. The side wall 52 includes an outer surface 41, an inner surface 42, and an end surface 43. The end surface 43 is connected to the outer surface 41 and the inner surface 42. The metal part 2b is the drawn product 40b in which a deep groove 48 is formed in the outer peripheral region of the end surface 43 in the radial direction of the drawn product 40b.

[0065] The manufacturing method of the metal part 2b of this embodiment is the same as the manufacturing method of the metal part 2 of embodiment 1. Specifically, as shown in FIG. 9, a metal workpiece 40 is fixed using a fixing member 30. For example, the fixing member 30 is fitted into the internal space of the drawn product 40b defined by the inner surface 42. The fixing member 30 contacts the inner surface 42 to fix the drawn product 40b. As shown in FIG. 9, a guide member 20 is arranged opposite a first portion (e.g., a side wall 52) of the metal workpiece 40 with a gap therebetween. The first portion of the metal workpiece 40 includes an end surface 43. The guide member 20 is arranged opposite an outer surface 41 of the side wall 52 with a gap therebetween.

[0066] As shown in FIG. 9 , a first punch 10 including a rounded first tip 13 is used to form a deep groove 48 in the end surface 43 of the metal workpiece 40. The deep groove 48 is formed by splitting a first portion of the metal workpiece 40 into a first metal portion 46 and a first metal piece 47 while moving the first tip 13 of the first punch 10 from the end surface 43 of the metal workpiece 40 toward the interior of the metal workpiece 40. The deep groove 48 is formed between the first metal portion 46 and the first metal piece 47. The first metal piece 47 is guided toward the guide member 20 by the first inclined surface 14 of the first punch 10.

[0067] While the first tip 13 of the first punch 10 is moved from the end face 43 of the metal workpiece 40 to the interior of the metal workpiece 40, the first metal piece 47 comes into contact with and is guided by the guide member 20. The first metal piece 47 is deformed by the guide member 20 into a metal piece extending along the axial direction (z direction) of the first punch 10. While the first punch 10 is moved relative to the metal workpiece 40 to process the metal workpiece 40, the guide member 20 does not move relative to the metal workpiece 40, and the position of the guide member 20 relative to the metal workpiece 40 is maintained. As shown in FIG. 10 , the first punch 10 is moved away from the metal workpiece 40. In this way, a metal part 2b is obtained.

[0068] Embodiment 3

[0069] 11 and 12, a method for manufacturing a metal part 2c according to a third embodiment using the metal part manufacturing apparatus 1 will be described. The method for manufacturing a metal part 2c according to the present embodiment includes the same steps as the method for manufacturing a metal part 2 according to the first embodiment, and achieves the same effects as the method for manufacturing a metal part 2 according to the first embodiment, but differs from the method for manufacturing a metal part 2 according to the first embodiment in the following respects.

[0070] In this embodiment, the metal workpiece 40 is a hollow metal workpiece, and the hollow metal workpiece is, for example, a burred product 40c formed by stretch flange processing. The burred product 40c includes a tubular portion 54 and a flange portion 55. The tubular portion 54 includes an outer surface 41, an inner surface 42, and an end surface 43. The end surface 43 is connected to the outer surface 41 and the inner surface 42. The flange portion 55 is connected to the end of the tubular portion 54 opposite the end surface 43. The metal part 2c is the burred product 40c or the burred product 40c in which a deep groove 48 is formed in the outer peripheral region of the end surface 43 in the radial direction of the tubular portion 54.

[0071] The manufacturing method of the metal part 2c of this embodiment is the same as the manufacturing method of the metal part 2 of embodiment 1. Specifically, as shown in FIG. 11, a metal workpiece 40 is fixed using a fixing member 30. For example, the fixing member 30 is fitted into a hole in the tubular portion 54 of the burred product 40c, which is defined by the inner surface 42. The fixing member 30 contacts the inner surface 42 to fix the burred product 40c. As shown in FIG. 11, a guide member 20 is arranged opposite a first portion (e.g., the tubular portion 54) of the metal workpiece 40 with a gap therebetween. The first portion of the metal workpiece 40 includes an end surface 43. The guide member 20 is arranged opposite an outer surface 41 of the tubular portion 54 with a gap therebetween.

[0072] As shown in FIG. 11 , a first punch 10 including a rounded first tip 13 is used to form a deep groove 48 in the end surface 43 of the metal workpiece 40. The deep groove 48 is formed by splitting a first portion of the metal workpiece 40 into a first metal portion 46 and a first metal piece 47 while moving the first tip 13 of the first punch 10 from the end surface 43 of the metal workpiece 40 toward the interior of the metal workpiece 40. The deep groove 48 is formed between the first metal portion 46 and the first metal piece 47. The first metal piece 47 is guided toward the guide member 20 by the first inclined surface 14 of the first punch 10.

[0073] While the first tip 13 of the first punch 10 is moved from the end face 43 of the metal workpiece 40 to the interior of the metal workpiece 40, the first metal piece 47 comes into contact with and is guided by the guide member 20. The first metal piece 47 is deformed by the guide member 20 into a metal piece extending along the axial direction (z direction) of the first punch 10. While the first punch 10 is moved relative to the metal workpiece 40 to process the metal workpiece 40, the guide member 20 does not move relative to the metal workpiece 40, and the position of the guide member 20 relative to the metal workpiece 40 is maintained. As shown in FIG. 12 , the first punch 10 is moved away from the metal workpiece 40. In this way, a metal part 2c is obtained.

[0074] Embodiment 4

[0075] 13 and 14, a method for manufacturing a metal part 2d according to a fourth embodiment using the metal part manufacturing apparatus 1 will be described. The method for manufacturing a metal part 2d according to the present embodiment includes the same steps as the method for manufacturing a metal part 2 according to the first embodiment, and achieves the same effects as the method for manufacturing a metal part 2 according to the first embodiment, but differs from the method for manufacturing a metal part 2 according to the first embodiment in the following respects.

[0076] In this embodiment, the metal workpiece 40 is a metal rod 40d. In this embodiment, the cross-sectional shape of the metal rod 40d in a cross section perpendicular to the longitudinal direction (axial direction, z direction) of the metal rod 40d is circular. The metal rod 40d includes an outer surface 41 and an end surface 43. The end surface 43 is connected to the outer surface 41. The end surface 43 extends, for example, along the x direction and the y direction. The metal rod 40d has a deep groove 48 formed in the outer peripheral region of the end surface 43 in the radial direction of the metal rod 40d.

[0077] The manufacturing method of the metal part 2d of this embodiment is the same as the manufacturing method of the metal part 2 of embodiment 1. Specifically, as shown in FIG. 13, a metal workpiece 40 is fixed using a fixing member 30. For example, the fixing member 30 is brought into contact with the outer surface 41 to fix a metal rod 40d. As shown in FIG. 13, a guide member 20 is arranged opposite a first portion of the metal workpiece 40 with a gap therebetween. The first portion of the metal workpiece 40 includes an end surface 43. The guide member 20 is arranged opposite the outer surface 41 of the metal rod 40d with a gap therebetween. The guide member 20 may be connected to the fixing member 30 (see FIGS. 13 and 14) or may be arranged separately from the fixing member 30.

[0078] As shown in FIG. 13 , a first punch 10 including a rounded first tip 13 is used to form a deep groove 48 in an end surface 43 of a metal workpiece 40. The deep groove 48 is formed by splitting a first portion of the metal workpiece 40 into a first metal portion 46 and a first metal piece 47 while moving the first tip 13 of the first punch 10 from the end surface 43 of the metal workpiece 40 toward the interior of the metal workpiece 40. The deep groove 48 is formed between the first metal portion 46 and the first metal piece 47. The first metal piece 47 is guided toward the guide member 20 by the first inclined surface 14 of the first punch 10.

[0079] While the first tip 13 of the first punch 10 is moved from the end face 43 of the metal workpiece 40 to the interior of the metal workpiece 40, the first metal piece 47 comes into contact with and is guided by the guide member 20. The first metal piece 47 is deformed by the guide member 20 into a metal piece extending along the axial direction (z direction) of the first punch 10. While the first punch 10 is moved relative to the metal workpiece 40 to process the metal workpiece 40, the guide member 20 does not move relative to the metal workpiece 40, and the position of the guide member 20 relative to the metal workpiece 40 is maintained. As shown in FIG. 14 , the first punch 10 is moved away from the metal workpiece 40. In this way, a metal part 2d is obtained.

[0080] Embodiment 5

[0081] A metal part manufacturing apparatus 1e according to embodiment 5 will be described with reference to Figures 15 and 16. The metal part manufacturing apparatus 1e according to this embodiment has a similar configuration to the metal part manufacturing apparatus 1 according to embodiment 1, but differs from the metal part manufacturing apparatus 1 according to embodiment 1 mainly in the following points.

[0082] In the metal part manufacturing apparatus 1e, the first punch 10 includes an outer surface 11, an inner surface 12, a rounded first tip 13, and a first inclined surface 14. The rounded first tip 13 is connected to the outer surface 11 and the first inclined surface 14. The first inclined surface 14 is connected to the rounded first tip 13 and the inner surface 12. The first inclined surface 14 is inclined so as to move away from the outer surface 11 as it moves away from the rounded first tip 13. The first inclined surface 14 is inclined so as to move away from the metal workpiece 40 as it moves away from the rounded first tip 13. In a cross section along the axial direction (z direction) of the first punch 10, the first inclined surface 14 is an inclined straight line inclined with respect to the axial direction of the first punch 10.

[0083] In the metal part manufacturing apparatus 1e, the guide member 20 is, for example, a solid guide member. The guide member 20 faces the inner surface 42 of the metal pipe 40a. The fixing member 30 is, for example, a hollow fixing member. The fixing member 30 faces and contacts the outer surface 41 of the metal pipe 40a.

[0084] A method for manufacturing a metal part 2e according to a fifth embodiment using a metal part manufacturing apparatus 1e will be described with reference to Figures 15 and 16. The method for manufacturing a metal part 2e according to the present embodiment includes the same steps as the method for manufacturing a metal part 2 according to the first embodiment, but differs from the method for manufacturing a metal part 2 according to the first embodiment in the following respects.

[0085] The metal part 2e is a metal tube 40a in which a deep groove 48 is formed in the inner circumferential region of an end face 43 in the radial direction of the metal tube 40a.

[0086] In the manufacturing method of the metal part 2e of this embodiment, as shown in FIG. 15, a metal workpiece 40 is fixed using a fixing member 30. For example, the fixing member 30 is brought into contact with the outer surface 41 of the metal tube 40a to fix the metal tube 40a. As shown in FIG. 15, a guide member 20 is arranged opposite a first portion of the metal workpiece 40 with a gap therebetween. The first portion of the metal workpiece 40 includes an end surface 43. The guide member 20 is arranged opposite an inner surface 42 of the metal tube 40a with a gap therebetween.

[0087] As shown in FIG. 15 , a deep groove 48 is formed in the end surface 43 of a metal workpiece 40 using a first punch 10 including a rounded first tip 13. The deep groove 48 is formed by splitting a first portion of the metal workpiece 40 into a first metal portion 46 and a first metal piece 47 while moving the first tip 13 of the first punch 10 from the end surface 43 of the metal workpiece 40 toward the interior of the metal workpiece 40. In a cross section along the axial direction (z direction) of the first punch 10, the outer surface 11 is a straight line extending in the axial direction of the first punch 10, while the first inclined surface 14 is an inclined line inclined relative to the axial direction of the first punch 10. Therefore, the first metal piece 47 is formed only in the inner surface 42 of the metal tube 40a. The deep groove 48 is formed between the first metal portion 46 and the first metal piece 47. The first metal piece 47 is guided toward the guide member 20 by the first inclined surface 14 of the first punch 10.

[0088] While the first tip 13 of the first punch 10 is moved from the end face 43 of the metal workpiece 40 to the interior of the metal workpiece 40, the first metal piece 47 comes into contact with and is guided by the guide member 20. The first metal piece 47 is deformed by the guide member 20 into a metal piece extending along the axial direction (z direction) of the first punch 10. While the first punch 10 is moved relative to the metal workpiece 40 to process the metal workpiece 40, the guide member 20 does not move relative to the metal workpiece 40, and the position of the guide member 20 relative to the metal workpiece 40 is maintained. As shown in FIG. 16 , the first punch 10 is moved away from the metal workpiece 40. In this way, a metal part 2e is obtained.

[0089] The metal component manufacturing apparatus 1e and the method for manufacturing a metal component 2e according to the present embodiment achieve the same effects as the metal component manufacturing apparatus 1 and the method for manufacturing a metal component 2 according to the first embodiment, but differ from the metal component manufacturing apparatus 1 and the method for manufacturing a metal component 2 according to the first embodiment in the following respects. In the present embodiment, even when the outer diameter of the metal component 2e needs to be equal to the outer diameter of the metal tube 40a, a deep groove 48 can be formed in the inner peripheral region of the radial end face 43 of the metal tube 40a.

[0090] Embodiment 6

[0091] A metal part manufacturing apparatus 1f according to embodiment 6 will be described with reference to Figures 17 and 18. The metal part manufacturing apparatus 1f according to this embodiment has a similar configuration to the metal part manufacturing apparatus 1 according to embodiment 1, but differs from the metal part manufacturing apparatus 1 according to embodiment 1 mainly in the following points.

[0092] The metal part manufacturing apparatus 1f further includes a second punch 60. The outer diameter of the second punch 60 is smaller than the outer diameter of the first punch 10, and the inner diameter of the second punch 60 is smaller than the inner diameter of the first punch 10. The second punch 60 is disposed inside the first punch 10.

[0093] The second punch 60 includes an outer surface 61, an inner surface 62, a rounded second tip 63, and a second inclined surface 64. The rounded second tip 63 is connected to the outer surface 61 and the second inclined surface 64. The second inclined surface 64 is connected to the rounded second tip 63 and the inner surface 62. The second inclined surface 64 is inclined in the opposite direction to the first inclined surface 14 with respect to the outer surface 61 or the inner surface 62. The second inclined surface 64 is inclined so as to move away from the outer surface 61 as it moves away from the rounded second tip 63. The second inclined surface 64 is inclined so as to move away from the metal workpiece 40 as it moves away from the rounded second tip 63. In a cross section along the axial direction (z direction) of the second punch 60, the second inclined surface 64 is an inclined straight line inclined with respect to the axial direction of the second punch 60.

[0094] The guide member 20 includes a first guide member 21 and a second guide member 22. The first guide member 21 is, for example, a hollow guide member. The second guide member 22 is, for example, a solid guide member. The first guide member 21 and the second guide member 22 are arranged opposite each other with a gap in between at a first portion of the metal workpiece 40. The first guide member 21 is arranged opposite the outer surface 41 of the metal tube 40a, similar to the guide member 20 of the first embodiment. The gap between the outer surface 41 of the metal tube 40a and the first guide member 21 is larger than the thickness T1 of the first punch 10. The second guide member 22 is arranged opposite the inner surface 42 of the metal tube 40a, similar to the guide member 20 of the fifth embodiment. The gap between the inner surface 42 of the metal tube 40a and the second guide member 22 is larger than the thickness T2 of the second punch 60.

[0095] The inner surface of the first guide member 21 functions as a guide surface for the first metal piece 47. The inner surface of the first guide member 21 extends in the axial direction (z direction) of the first punch 10. In a cross section along the axial direction of the first punch 10, the inner surface of the first guide member 21 is a straight line extending in the axial direction of the first punch 10. The outer surface of the second guide member 22 functions as a guide surface for the second metal piece 57. The outer surface of the second guide member 22 extends in the axial direction (z direction) of the second punch 60. In a cross section along the axial direction of the second punch 60, the outer surface of the second guide member 22 is a straight line extending in the axial direction of the second punch 60. While the first punch 10 is moved relative to the metal workpiece 40 to machine the metal workpiece 40, the first guide member 21 and the second guide member 22 do not move relative to the metal workpiece 40, and the positions of the first guide member 21 and the second guide member 22 relative to the metal workpiece 40 are maintained.

[0096] As shown in FIG. 17 , while the first tip 13 of the first punch 10 is being moved from the end face 43 of the metal workpiece 40 to the interior of the metal workpiece 40, the first guide member 21 contacts and guides the first metal piece 47. The first metal piece 47 is deformed by the first guide member 21 into a metal piece extending along the axial direction (z direction) of the first punch 10. The first metal piece 47 deformed by the first guide member 21 extends, for example, parallel to the outer surface of the first metal portion 46. In this way, a deep groove 48 is formed in the end face 43 of the metal workpiece 40, as shown in FIG. 18 .

[0097] While the second tip 63 of the second punch 60 is moving from the end face 43 of the metal workpiece 40 to the interior of the metal workpiece 40, the second guide member 22 contacts and guides the second metal piece 57. The second metal piece 57 is deformed by the second guide member 22 into a metal piece extending along the axial direction (z direction) of the second punch 60. The second metal piece 57 deformed by the second guide member 22 extends, for example, parallel to the inner surface of the first metal portion 46. In this way, as shown in FIG. 18 , a deep groove 58 is formed in the end face 43 of the metal workpiece 40. The depth direction of the deep groove 58 is the axial direction (z direction) or the longitudinal direction (z direction) of the metal workpiece 40. The width direction of the deep groove 58 is the radial direction of the metal workpiece 40.

[0098] 17 and 18, a method for manufacturing a metal part 2f according to the sixth embodiment using a metal part manufacturing apparatus 1f will be described. The method for manufacturing a metal part 2f according to the sixth embodiment includes the same steps as the method for manufacturing a metal part 2 according to the first embodiment, but differs from the method for manufacturing a metal part 2 according to the first embodiment in the following respects.

[0099] The metal part 2f of this embodiment is a metal tube 40a in which deep grooves 48 and deep grooves 58 are formed in the outer peripheral region and inner peripheral region of the end face 43 in the radial direction of the metal tube 40a.

[0100] In the method for manufacturing metal part 2f of the present embodiment, deep groove 48 is formed by the same steps as in the method for manufacturing metal part 2 of embodiment 1. However, in this embodiment, a first guide member 21 is used to form deep groove 48 instead of guide member 20 of embodiment 1. Furthermore, in the method for manufacturing metal part 2f of the present embodiment, deep groove 58 is formed using second punch 60 by the same steps as in the method for manufacturing metal part 2e of embodiment 5. The method for forming deep groove 58 will be described in more detail.

[0101] As shown in FIG. 17 , a deep groove 58 is formed in the end surface 43 of the metal workpiece 40 using a second punch 60 including a rounded second tip 63. The deep groove 58 is formed by splitting a first portion of the metal workpiece 40 into a first metal portion 46 and a second metal piece 57 while moving the second tip 63 of the second punch 60 from the end surface 43 of the metal workpiece 40 toward the interior of the metal workpiece 40. In a cross section along the axial direction (z direction) of the second punch 60, the outer surface 61 is a straight line extending in the axial direction of the second punch 60, while the second inclined surface 64 is a straight line inclined relative to the axial direction of the second punch 60. Therefore, the second metal piece 57 is formed only in the inner surface 42 of the metal tube 40a. The deep groove 58 is formed between the first metal portion 46 and the second metal piece 57. The second metal piece 57 is guided toward the second guide member 22 by the second inclined surface 64 of the second punch 60.

[0102] While the second tip 63 of the second punch 60 is being moved from the end face 43 of the metal workpiece 40 to the interior of the metal workpiece 40, the second metal piece 57 comes into contact with the second guide member 22 and is guided by the second guide member 22. The second metal piece 57 is deformed by the second guide member 22 to become a metal piece extending along the axial direction (z direction) of the second punch 60. While the second punch 60 is being moved relative to the metal workpiece 40 to process the metal workpiece 40, the second guide member 22 does not move relative to the metal workpiece 40, and the position of the second guide member 22 relative to the metal workpiece 40 is maintained.

[0103] As shown in Fig. 18, the second punch 60 is moved away from the metal workpiece 40. In this manner, the metal part 2f is obtained. In this embodiment, the deep grooves 48 and 58 are formed simultaneously. The deep grooves 48 and 58 may be formed before or after the deep grooves 48 and 58.

[0104] (Variation)

[0105] The second tip 63 of the second punch 60 does not have to be rounded.

[0106] The metal part manufacturing apparatus 1f and the method for manufacturing a metal part 2f according to this embodiment have the following advantages in addition to the advantages of the metal part manufacturing apparatus 1 and the method for manufacturing a metal part 2 according to the first embodiment.

[0107] In this embodiment, deep grooves 48 and deep grooves 58 can be formed in the outer peripheral region and inner peripheral region of the end face 43 in the radial direction of the metal tube 40a, respectively.

[0108] Furthermore, the second metal piece 57 is deformed by the second guide member 22. The shape of the deep groove 58 formed in the metal workpiece 40 can be controlled while the metal workpiece 40 is being split using the second punch 60. Furthermore, when the second metal piece 57 is deformed by the second guide member 22, the second metal piece 57 is subjected to deformation resistance from the second guide member 22. Due to this deformation resistance, a portion of the metal material that constitutes the metal workpiece 40 accumulates in the portion of the metal workpiece 40 that faces the second tip 63. Therefore, it is possible to prevent cracks that occur in the metal workpiece 40 from occurring deeper than the second tip 63 of the second punch 60.

[0109] In this embodiment, the second tip 73 of the second punch 70 is a rounded tip.

[0110] This reduces the concentration of the load applied to the metal workpiece 40 at the second tip 63 of the second punch 60. This prevents cracks from occurring in the metal workpiece 40 that are deeper than the second tip 63 of the second punch 60.

[0111] Embodiment 7

[0112] 19 to 21, a metal part manufacturing apparatus 1g according to the seventh embodiment will be described. The metal part manufacturing apparatus 1g according to the present embodiment has a configuration similar to that of the metal part manufacturing apparatus 1 according to the first embodiment, but differs from the metal part manufacturing apparatus 1 according to the first embodiment in the following respects.

[0113] The first punch 10 includes an outer surface 11, an inner surface 12, a rounded first tip 13, a first inclined surface 14, and a second inclined surface 15. The outer surface 11 and the inner surface 12 each extend in the axial direction (z direction) of the first punch 10. In a cross section along the axial direction of the first punch 10, the outer surface 11 and the inner surface 12 each are straight lines extending in the axial direction of the first punch 10. The rounded first tip 13 is connected to the first inclined surface 14 and the second inclined surface 15.

[0114] The first inclined surface 14 is connected to the rounded first tip 13 and the outer surface 11. The first inclined surface 14 is inclined so as to move away from the inner surface 12 as it moves away from the rounded first tip 13. In a cross section along the axial direction (z direction) of the first punch 10, the first inclined surface 14 is an inclined straight line inclined with respect to the axial direction of the first punch 10.

[0115] The second inclined surface 15 is connected to the rounded first tip 13 and the inner surface 12. The second inclined surface 15 is inclined toward the opposite side of the first inclined surface 14 with respect to the outer surface 11 or the inner surface 12. The second inclined surface 15 is inclined so as to move away from the outer surface 11 as it moves away from the rounded first tip 13. In a cross section along the axial direction (z direction) of the first punch 10, the second inclined surface 15 is an inclined straight line inclined with respect to the axial direction of the first punch 10.

[0116] As shown in Figures 19 and 20, the first tip 13 of the first punch 10 is moved from the end face 43 of the metal workpiece 40 toward the interior of the metal workpiece 40, splitting the first portion of the metal workpiece 40 into a first metal portion 46 and a first metal piece 47. The first punch 10 includes a first inclined surface 14 and a second inclined surface 15 connected to the rounded first tip 13. Therefore, the first metal piece 47 is formed on the outer surface of the metal tube 40a. The first metal portion 46 is a second metal piece formed on the inner surface of the metal tube 40a. The first inclined surface 14 guides the first metal piece 47 toward the first guide member 21. The second inclined surface 15 guides the first metal portion 46, which is the second metal piece, toward the second guide member 22.

[0117] Like the guide member 20 of the sixth embodiment, the guide member 20 of the present embodiment includes a first guide member 21 and a second guide member 22. The inner surface of the first guide member 21 functions as a guide surface for the first metal piece 47. The inner surface of the second guide member 22 functions as a guide surface for the first metal portion 46, which is the second metal piece.

[0118] While the first tip 13 of the first punch 10 is being moved from the end face 43 of the metal workpiece 40 to the interior of the metal workpiece 40, the first guide member 21 contacts and guides the first metal piece 47. The first metal piece 47 is deformed by the first guide member 21 into a metal piece extending along the axial direction (z direction) of the first punch 10. While the first tip 13 of the first punch 10 is being moved from the end face 43 of the metal workpiece 40 to the interior of the metal workpiece 40, the second guide member 22 contacts and guides the first metal portion 46, which is the second metal piece. The first metal portion 46 is deformed by the first guide member 21 into a metal piece extending along the axial direction of the first punch 10. The first metal portion 46 deformed by the first guide member 21 extends, for example, parallel to the first metal piece 47. In this way, deep grooves 48 are formed in the end surface 43 of the metal workpiece 40, as shown in FIG.

[0119] 19 to 21, a method for manufacturing a metal part 2g according to the seventh embodiment using a metal part manufacturing apparatus 1g will be described. The method for manufacturing a metal part 2g according to the present embodiment includes the same steps as the method for manufacturing a metal part 2 according to the first embodiment, but differs from the method for manufacturing a metal part 2 according to the first embodiment in the following respects.

[0120] The metal part 2g is a metal tube 40a in which a deep groove 48 is formed in a central region of an end face 43 in the radial direction of the metal tube 40a. The width of the deep groove 48 in the metal part 2g of the present embodiment is larger than the width of the deep groove 48 in the metal part 2 of the first embodiment.

[0121] The manufacturing method of the metal part 2g of this embodiment is the same as the manufacturing method of the metal part 2 of embodiment 1. Specifically, a metal workpiece 40 is fixed using a fixing member 30 (not shown). As shown in FIG. 19 , similar to the guide member 20 of embodiment 6, the guide member 20 is arranged facing a first portion (e.g., side wall 52) of the metal workpiece 40 with a gap therebetween. The first guide member 21 is arranged facing the outer surface 41 of the metal tube 40a. The gap between the outer surface 41 of the metal tube 40a and the first guide member 21 is greater than the thickness of the first metal piece 47. The second guide member 22 is arranged facing the inner surface 42 of the metal tube 40a. The gap between the inner surface 42 of the metal tube 40a and the second guide member 22 is greater than the thickness of the first metal portion 46, which is the second metal piece.

[0122] As shown in FIGS. 19 and 20 , a first punch 10 including a rounded first tip 13 is used to form a deep groove 48 in the end surface 43 of a metal workpiece 40. The deep groove 48 is formed by splitting a first portion of the metal workpiece 40 into a first metal piece 47 and a first metal portion 46, which is a second metal piece, while moving the first tip 13 of the first punch 10 from the end surface 43 of the metal workpiece 40 toward the interior of the metal workpiece 40. The deep groove 48 is formed between the first metal piece 47 and the first metal portion 46, which is the second metal piece. The first metal piece 47 is guided toward the first guide member 21 by the first inclined surface 14 of the first punch 10. The first metal portion 46, which is the second metal piece, is guided toward the second guide member 22 by the second inclined surface 15 of the first punch 10.

[0123] While the first tip 13 of the first punch 10 is being moved from the end face 43 of the metal workpiece 40 to the interior of the metal workpiece 40, the first metal piece 47 comes into contact with and is guided by the first guide member 21. The first metal piece 47 is deformed by the first guide member 21 to become a metal piece extending along the axial direction (z direction) of the first punch 10. While the first tip 13 of the first punch 10 is being moved from the end face 43 of the metal workpiece 40 to the interior of the metal workpiece 40, the first metal portion 46, which is the second metal piece, comes into contact with and is guided by the second guide member 22. The first metal portion 46 is deformed by the second guide member 22 to become a metal piece extending along the axial direction of the first punch 10. While the first punch 10 is moved relative to the metal workpiece 40 to process the metal workpiece 40, the first guide member 21 and the second guide member 22 do not move relative to the metal workpiece 40, and the position of the first guide member 21 relative to the metal workpiece 40 and the position of the second guide member 22 relative to the metal workpiece 40 are maintained.

[0124] When the first punch 10 is used to process the metal workpiece 40, the first inclined surface 14 of the first punch 10 receives a reaction force F1, which is a force required for plastic deformation of the metal workpiece 40. The second inclined surface 15 of the first punch 10 receives a reaction force F2, which is a force required for plastic deformation of the metal workpiece 40. Because the second inclined surface 15 is inclined opposite to the first inclined surface 14, the direction of the reaction force F2 is opposite to the direction of the reaction force F1 in the direction perpendicular to the movement direction of the first punch 10 (z direction). Part or all of the component of the reaction force F1 that is perpendicular to the movement direction of the first punch 10 is offset by the component of the reaction force F2 that is perpendicular to the movement direction of the first punch 10. The load that the first punch 10 receives in the direction perpendicular to the movement direction of the first punch 10 during processing of the metal workpiece 40 is reduced. This reduces damage or wear to the first punch 10 when processing the metal workpiece 40.

[0125] 21, the first punch 10 is moved away from the metal workpiece 40. In this way, a metal part 2g is obtained.

[0126] The metal part manufacturing apparatus 1g and the method for manufacturing a metal part 2g of this embodiment have the following advantages in addition to the advantages of the metal part manufacturing apparatus 1 and the method for manufacturing a metal part 2 of the first embodiment.

[0127] In the metal part manufacturing apparatus 1g of this embodiment and the manufacturing method of the metal part 2g of this embodiment, the first punch 10 is connected to the first tip 13 and includes a second inclined surface 15 that is inclined opposite to the first inclined surface 14.

[0128] Therefore, a deep groove 48 having a wider width can be formed on the end surface 43 of the metal workpiece 40.

[0129] Furthermore, the load that the first punch 10 receives along a direction perpendicular to the direction of movement (z direction) of the first punch 10 when machining the metal workpiece 40 is reduced. This reduces damage or wear to the first punch 10 when machining the metal workpiece 40. This improves the durability of the first punch 10 when machining the metal workpiece 40.

[0130] Embodiment 8

[0131] 22 to 25, a method for manufacturing a metal part 2h according to the eighth embodiment using the metal part manufacturing apparatus 1 will be described. The method for manufacturing a metal part 2h according to the eighth embodiment includes the same steps as the method for manufacturing a metal part 2 according to the first embodiment, but differs from the method for manufacturing a metal part 2 according to the first embodiment in the following respects.

[0132] The metal tube 40a of this embodiment further includes an end face 44 opposite to the end face 43. The end face 44 is connected to the outer surface 41 and the inner surface 42. The metal tube 40a includes a second portion including the end face 44 in addition to a first portion including the end face 43. The metal part 2h of this embodiment is a metal tube 40a in which deep grooves 48 and 48b are formed in the outer peripheral regions of the end face 43 and the end face 44 in the radial direction of the metal tube 40a, respectively. The depth direction of the deep groove 48b is the axial direction (z direction) of the metal workpiece 40 or the longitudinal direction (z direction) of the metal workpiece 40. The width direction of the deep groove 48b is the radial direction of the metal workpiece 40.

[0133] The method for manufacturing the metal part 2h of this embodiment is the same as the method for manufacturing the metal part 2 of embodiment 1. As shown in Figures 22 and 23, a deep groove 48 is formed in the end surface 43 of the metal tube 40a by the same steps as in the method for manufacturing the metal part 2 of embodiment 1 (see Figures 5 to 8). Then, as shown in Figures 24 and 25, a deep groove 48b is formed in the end surface 44 of the metal tube 40a by the same steps as in the method for manufacturing the metal part 2 of embodiment 1.

[0134] Specifically, as shown in FIG. 23, after the first punch 10 is separated from the metal workpiece 40, the fixing member 30 is removed from the first portion of the metal workpiece 40. Then, the fixing member 30 is fitted into the hole of the metal tube 40a defined by the inner surface 42. The fixing member 30 contacts the inner surface 42 to fix the second portion of the metal workpiece 40, as shown in FIG. 24. The second portion of the metal workpiece 40 includes an end surface 44. The guide member 20 is arranged opposite the second portion of the metal workpiece 40 with a gap therebetween. The guide member 20 is arranged opposite the outer surface 41 of the metal tube 40a with a gap therebetween.

[0135] As shown in FIG. 24 , a deep groove 48b is formed in the end surface 44 of a metal workpiece 40 using a first punch 10 including a rounded first tip 13. Forming the deep groove 48b involves splitting a second portion of the metal workpiece 40 into a second metal portion 46b and a second metal piece 47b while moving the first tip 13 of the first punch 10 from the end surface 44 of the metal workpiece 40 toward the interior of the metal workpiece 40. In a cross section along the axial direction (z direction) of the first punch 10, the inner surface 12 is a straight line extending in the axial direction of the first punch 10, while the first inclined surface 14 is a straight line inclined relative to the axial direction of the first punch 10. Therefore, the second metal piece 47b is formed only on the outer surface 41 of the metal tube 40a. The deep groove 48b is formed between the second metal portion 46b and the second metal piece 47b. As shown in FIG. 24, the second metal piece 47b is guided toward the guide member 20 by the first inclined surface 14 of the first punch 10.

[0136] While the first tip 13 of the first punch 10 is moved from the end face 44 of the metal workpiece 40 to the interior of the metal workpiece 40, the second metal piece 47b is brought into contact with the guide member 20, and the guide member 20 guides the second metal piece 47b. The second metal piece 47b is deformed by the guide member 20 to become a metal piece extending along the axial direction (z direction) of the first punch 10. The second metal piece 47b deformed by the guide member 20 extends, for example, parallel to the outer surface of the second metal portion 46b. While the first punch 10 is moved relative to the metal workpiece 40 to process the metal workpiece 40, the guide member 20 does not move relative to the metal workpiece 40, and the position of the guide member 20 relative to the metal workpiece 40 is maintained.

[0137] 25, the first punch 10 is moved away from the metal workpiece 40. In this way, a metal part 2h is obtained.

[0138] The method for manufacturing a metal part 2h of this embodiment has the same effects as the method for manufacturing a metal part 2 of embodiment 1, but differs from the method for manufacturing a metal part 2 of embodiment 1 in the following respects: In this embodiment, deep grooves 48, 48b can be formed on both end faces 43 and 44 of a metal workpiece 40.

[0139] Embodiment 9

[0140] 26 to 31, a metal part manufacturing apparatus 1i according to embodiment 9 will be described. The metal part manufacturing apparatus 1i according to this embodiment has a configuration similar to that of the metal part manufacturing apparatus 1 according to embodiment 1, but differs from the metal part manufacturing apparatus 1 according to embodiment 1 in the following respects.

[0141] In the metal part manufacturing apparatus 1i, the guide member 20 includes a protrusion 23 that protrudes from the tip of the guide member 20. The protrusion 23 protrudes from the side of the guide member 20 that is closer to the first punch 10. The protrusion 23 protrudes from the side of the guide member 20 that is closer to the metal workpiece 40. As shown in FIGS. 28 to 30 , by moving the guide member 20 relative to the metal workpiece 40, the first metal piece 47 is ironed by the protrusion 23 of the guide member 20.

[0142] 26 to 31, a method for manufacturing a metal part 2i according to the ninth embodiment using a metal part manufacturing apparatus 1i will be described. The method for manufacturing a metal part 2i according to the present embodiment includes the same steps as the method for manufacturing a metal part 2 according to the first embodiment, but differs from the method for manufacturing a metal part 2 according to the first embodiment in the following respects.

[0143] As shown in FIG. 31, in a metal part 2i of this embodiment, the first metal piece 47 is thinner and longer than in the metal part 2 of the first embodiment.

[0144] 26 and 27, in the method for manufacturing a metal part 2i of the present embodiment, a deep groove 48 is formed in an end surface 43 of a metal workpiece 40 using a first punch 10 including a rounded first tip 13 by steps similar to those in the method for manufacturing a metal part 2 of the first embodiment (see FIGS. 5 to 7). In the present embodiment, the guide member 20 includes a protrusion 23 that protrudes from the tip of the guide member 20.

[0145] 28 and 29, the guide member 20 is moved relative to the metal workpiece 40, and the first metal piece 47 is ironed by the protrusion 23 of the guide member 20. Specifically, when the guide member 20 is moved relative to the metal workpiece 40, the first metal piece 47 is sandwiched between the protrusion 23 and the outer surface 11 of the first punch 10. Therefore, the first metal piece 47 is ironed by the protrusion 23 of the guide member 20, and the thickness of the first metal piece 47 decreases and the length of the first metal piece 47 increases. After ironing the first metal piece 47, the guide member 20 is separated from the metal workpiece 40, as shown in FIG.

[0146] 31, the first punch 10 is moved away from the metal workpiece 40. In this way, the metal part 2i is obtained.

[0147] The metal part manufacturing apparatus 1i and the method for manufacturing a metal part 2i according to this embodiment have the following advantages in addition to the advantages of the metal part manufacturing apparatus 1 and the method for manufacturing a metal part 2 according to the first embodiment.

[0148] In the metal part manufacturing apparatus 1i of this embodiment, the guide member 20 includes a protrusion 23 that protrudes from the tip of the guide member 20 toward the side of the guide member 20 that is closer to the first punch 10. By moving the guide member 20 relative to the metal workpiece 40, the first metal piece 47 is ironed by the protrusion 23 of the guide member 20.

[0149] The method for manufacturing the metal part 2i of this embodiment further includes moving the guide member 20 relative to the metal workpiece 40 and ironing the first metal piece 47 with the protrusion 23 of the guide member 20. The protrusion 23 protrudes from the tip of the guide member 20 on a side of the guide member 20 that is closer to the first punch 10.

[0150] In the metal part manufacturing apparatus 1i of this embodiment and the manufacturing method of the metal part 2i of this embodiment, the first metal piece 47 is ironed by the protrusion 23 of the guide member 20, so that the thickness of the first metal piece 47 can be controlled with high precision.

[0151] Embodiment 10

[0152] 32 to 34, a metal part manufacturing apparatus 1j according to a tenth embodiment will be described. The metal part manufacturing apparatus 1j according to the present embodiment has a configuration similar to that of the metal part manufacturing apparatus 1 according to the first embodiment, but differs from the metal part manufacturing apparatus 1 according to the first embodiment in the following respects.

[0153] In the metal part manufacturing apparatus 1j, the first punch 10 includes a second inclined surface 15. The second inclined surface 15 is connected to the first tip 13 and the inner surface 12. The second inclined surface 15 is inclined in the opposite direction to the first inclined surface 14 with respect to the outer surface 11 or the inner surface 12. The second inclined surface 15 is inclined so as to approach the metal workpiece 40 as it moves away from the first tip 13. The second inclined surface 15 may be the same size as the first inclined surface 14, or may be smaller than the first inclined surface 14.

[0154] A method for manufacturing a metal part 2 according to the tenth embodiment using a metal part manufacturing apparatus 1j will be described with reference to Fig. 34. The method for manufacturing a metal part 2 according to the present embodiment includes the same steps as the method for manufacturing a metal part 2 according to the first embodiment (see Figs. 5 to 8), but differs in the following respects.

[0155] As shown in FIG. 34 , when a metal workpiece 40 is machined using the first punch 10, the first inclined surface 14 of the first punch 10 receives a reaction force F1, which is a force required for plastic deformation of the metal workpiece 40. The second inclined surface 15 of the first punch 10 receives a reaction force F2, which is a force required for plastic deformation of the metal workpiece 40. Because the second inclined surface 15 is inclined opposite to the first inclined surface 14, the direction of reaction force F2 is opposite to the direction of reaction force F1 in the direction perpendicular to the movement direction of the first punch 10 (z direction). Part or all of the component of reaction force F1 perpendicular to the movement direction of the first punch 10 is offset by the component of reaction force F2 perpendicular to the movement direction of the first punch 10. The load perpendicular to the movement direction of the first punch 10 that the first punch 10 receives during machining of the metal workpiece 40 is reduced. This reduces damage or wear to the first punch 10 during machining of the metal workpiece 40.

[0156] The metal part manufacturing apparatus 1j and the method for manufacturing a metal part 2 according to the present embodiment have the following advantages in addition to the advantages of the metal part manufacturing apparatus 1 and the method for manufacturing a metal part 2 according to the first embodiment.

[0157] In the metal part manufacturing apparatus 1j of this embodiment and the method for manufacturing a metal part 2 of this embodiment, the first punch 10 includes a second inclined surface 15 connected to the first tip 13 and inclined opposite to the first inclined surface 14.

[0158] Therefore, the load that the first punch 10 receives along the direction perpendicular to the movement direction (z direction) of the first punch 10 when machining the metal workpiece 40 is reduced. This reduces damage or wear of the first punch 10 when machining the metal workpiece 40. This improves the durability of the first punch 10 when machining the metal workpiece 40.

[0159] Embodiment 11

[0160] A metal part 2k according to embodiment 11 will be described with reference to Fig. 35. The metal part 2k according to this embodiment has a similar configuration to the metal part 2 according to embodiment 1, but differs from the metal part 2 according to embodiment 1 in the following respects.

[0161] The metal component 2k is a metal tube 40a having a cavity 68 formed in the outer surface 41. The cavity 68 is, for example, an enclosed space. Specifically, the metal component 2k further includes a sealing member 66 and a lid 67 in addition to the metal tube 40a. The cavity 68 is defined by the first metal portion 46, the first metal piece 47, and the sealing member 66.

[0162] The sealing member 66 is an elastically deformable member such as an O-ring. The sealing member 66 contacts the first metal portion 46 and the first metal piece 47, and closes the opening of the deep groove 48. In this way, the deep groove 48 becomes a cavity 68.

[0163] The lid 67 is formed of, for example, a metal. The lid 67 is not particularly limited, but may be formed of, for example, copper, aluminum, iron, a copper alloy, an aluminum alloy, or an iron alloy. The lid 67 includes a base portion 67a and a protrusion 67b protruding from the base portion 67a. The base portion 67a closes the opening of the metal tube 40a at, for example, the end surface 43 of the metal tube 40a. The protrusion 67b presses the sealing member 66. The protrusion 67b is fitted into the opening of the deep groove 48. The protrusion 67b may close the opening of the deep groove 48.

[0164] The cavity 68 may be filled with a fluid such as a liquid or gas. The cavity 68 may be evacuated to create a vacuum. This reduces heat conduction from the metal workpiece 40 to another member (not shown) adjacent to the metal workpiece 40, making it easier to heat, cool, or keep the metal workpiece 40 warm. The cavity 68 may be filled with a solid material such as a heat insulating material, a vibration-damping material, or a sound-proofing material. Filling the cavity 68 with a heat insulating material reduces heat conduction from the metal workpiece 40 to another member (not shown) adjacent to the metal workpiece 40. Filling the cavity 68 with a vibration-damping material reduces vibrations propagating through the metal workpiece 40. Filling the cavity 68 with a sound-proofing material reduces sound propagating through the metal workpiece 40.

[0165] A method for manufacturing a metal part 2k according to an eleventh embodiment will now be described. The method for manufacturing a metal part 2k according to this embodiment, following the method for manufacturing a metal part 2 according to the first embodiment, further includes closing the opening of the deep groove 48 to form a cavity 68 in the metal workpiece 40. Closing the opening of the deep groove 48 includes fitting a sealing member 66 into the opening of the deep groove 48. For example, the sealing member 66 is fitted into the opening of the deep groove 48 by pressing the sealing member 66 using the protrusion 67b of the lid 67. The method for manufacturing a metal part 2k according to this embodiment may further include filling the cavity 68 with a fluid or a solid, or may further include evacuating the cavity 68 to place it in a vacuum state.

[0166] (Variation)

[0167] A metal part 2l according to a modification of the present embodiment will be described with reference to FIG. 36 . The metal part 2l according to the modification of the present embodiment has the same configuration as the metal part 2k according to the present embodiment, but does not include a sealing member 66. In the metal part 2l according to the modification of the present embodiment, a cavity 68 is defined by a first metal portion 46, a first metal piece 47, and a lid 67. Specifically, a protrusion 67b of the lid 67 is fitted into the opening of the deep groove 48, closing the opening of the deep groove 48. In this way, the deep groove 48 becomes the cavity 68. The lid 67 is joined to the first metal portion 46 and the first metal piece 47. The lid 67 is welded to the first metal portion 46 and the first metal piece 47, for example. The protrusion 67b of the lid 67 is welded to the first metal portion 46 by a weld 69a. The protrusion 67b of the lid 67 is welded to the first metal portion 46 by a weld 69b. The lid 67 may be glued to the first metal portion 46 and the first metal piece 47, or may be crimped to the first metal portion 46 and the first metal piece 47.

[0168] A manufacturing method for a metal part 2l according to a modification of this embodiment will be described. The manufacturing method for the metal part 2l according to this modification of this embodiment is similar to the manufacturing method for the metal part 2k according to this embodiment, but differs from the manufacturing method for the metal part 2k according to this embodiment in the following respects. In the manufacturing method for the metal part 2l according to this modification of this embodiment, closing the opening of the deep groove 48 includes fitting a lid 67 into the opening of the deep groove 48 and joining or crimping the lid 67 to the first metal portion 46 and the first metal piece 47. Specifically, the protrusion 67b of the lid 67 is fitted into the opening of the deep groove 48. Then, the protrusion 67b of the lid 67 is joined to the first metal portion 46 and the first metal piece 47 by welding. A weld 69a is formed between the protrusion 67b of the lid 67 and the first metal portion 46. A weld 69b is formed between the protrusion 67b of the lid 67 and the first metal piece 47. The lid 67 may be glued to the first metal portion 46 and the first metal piece 47, or may be crimped to the first metal portion 46 and the first metal piece 47.

[0169] The method for manufacturing the metal parts 2k and 2l of this embodiment has the following advantages in addition to the advantages of the method for manufacturing the metal part 2 of the first embodiment.

[0170] The method for manufacturing the metal parts 2k and 2l of this embodiment further includes closing the openings of the deep grooves 48 to form cavities 68 in the metal workpiece 40.

[0171] Therefore, the cavity 68 can be filled with a fluid such as a liquid or a gas, which can facilitate heating, cooling, or keeping the metal workpiece 40 warm, reduce vibrations propagating through the metal workpiece 40, or reduce sounds propagating through the metal workpiece 40.

[0172] In the manufacturing method of the metal components 2k and 2l of this embodiment, closing the opening of the deep groove 48 includes fitting the sealing member 66 into the opening of the deep groove 48.

[0173] Therefore, the cavity 68 can be filled with a fluid such as a liquid or a gas, which can facilitate heating, cooling, or keeping the metal workpiece 40 warm, reduce vibrations propagating through the metal workpiece 40, or reduce sounds propagating through the metal workpiece 40.

[0174] In the manufacturing method of metal parts 2k, 2l of this embodiment, closing the opening of deep groove 48 includes fitting lid 67 into the opening of deep groove 48 and joining or crimping lid 67 to first metal portion 46 and first metal piece 47.

[0175] Therefore, the cavity 68 can be filled with a fluid such as a liquid or a gas, which can facilitate heating, cooling, or keeping the metal workpiece 40 warm, reduce vibrations propagating through the metal workpiece 40, or reduce sounds propagating through the metal workpiece 40.

[0176] Embodiment 12

[0177] A metal part manufacturing apparatus 1m according to embodiment 12 will be described with reference to Figures 37 and 38. The metal part manufacturing apparatus 1m of this embodiment has a similar configuration to the metal part manufacturing apparatus 1 of embodiment 1, but differs from the metal part manufacturing apparatus 1 of embodiment 1 in the following respects.

[0178] The metal part manufacturing apparatus 1m further includes a second punch 70. The second punch 70 is configured similarly to the first punch 10 of the fifth embodiment, but the outer diameter of the second punch 70 is smaller than the outer diameter of the first punch 10, and the inner diameter of the second punch 70 is smaller than the inner diameter of the first punch 10.

[0179] The second punch 70 includes an outer surface 71, an inner surface 72, a rounded second tip 73, and a second inclined surface 74. The rounded second tip 73 is connected to the inner surface 72 and the second inclined surface 74. The second inclined surface 74 is connected to the rounded second tip 73 and the outer surface 71. The second inclined surface 74 is inclined toward the same side as the first inclined surface 14 (see Figures 3 to 8) with respect to the outer surface 71 or the inner surface 72. The second inclined surface 74 is inclined so as to approach the outer surface 71 as it moves away from the rounded second tip 73. The second inclined surface 74 is inclined so as to move away from the metal workpiece 40 as it moves away from the rounded second tip 73. In a cross section along the axial direction (z direction) of the second punch 70, the second inclined surface 74 is an inclined straight line inclined with respect to the axial direction of the second punch 70.

[0180] 37 to 39, a method for manufacturing a metal part 2m according to embodiment 12 using a metal part manufacturing apparatus 1m will be described. The method for manufacturing a metal part 2m according to this embodiment includes the same steps as the method for manufacturing a metal part 2 according to embodiment 1, but differs from the method for manufacturing a metal part 2 according to embodiment 1 in the following respects.

[0181] As shown in FIG. 39 , the metal part 2m is a metal tube 40a having a cavity 68 formed in the outer surface 41, similar to the metal part 2k of the eleventh embodiment. In the metal part 2m, a second metal piece 77 is formed in the outer surface 41 of the metal tube 40a. The cavity 68 is defined by a first metal portion 46, a first metal piece 47, and a second metal piece 77. The first metal piece 47 is joined to the second metal piece 77 to close the opening of the deep groove 48. In this way, the deep groove 48 becomes the cavity 68. The first metal piece 47 is welded to the second metal piece 77 by, for example, a weld 69.

[0182] 37 to 39, the method for manufacturing a metal part 2m of this embodiment, following the method for manufacturing a metal part 2 of embodiment 1 (see FIGS. 5 to 8), further includes closing the openings of the deep grooves 48 to form cavities in the metal workpiece 40. Closing the openings of the deep grooves 48 includes the following steps.

[0183] As shown in FIG. 37 , the first metal portion 46 is split into a second metal portion 76 and a second metal piece 77 by moving the rounded second tip 73 of the second punch 70 from the end surface 43 into the inside of the first metal portion 46. In a cross section along the axial direction (z direction) of the second punch 70, the inner surface 72 is a straight line extending in the axial direction of the second punch 70, while the second inclined surface 74 is a straight line inclined relative to the axial direction of the second punch 70. Therefore, the second metal piece 77 is formed only on the outer surface of the first metal portion 46. The second metal piece 77 is guided toward the first metal piece 47 by the second inclined surface 74 of the second punch 70.

[0184] While the second tip 73 of the second punch 70 is being moved from the end face 43 into the inside of the first metal portion 46, the second metal piece 77 comes into contact with the first metal piece 47, which is in contact with the guide member 20, and is guided by the first metal piece 47. The second metal piece 77 is deformed by the first metal piece 47 to become a metal piece extending along the axial direction (z direction) of the second punch 70. While the second punch 70 is being moved relative to the first metal portion 46 to process the first metal portion 46, the guide member 20 does not move relative to the metal workpiece 40, and the position of the guide member 20 relative to the metal workpiece 40 is maintained. As shown in FIG. 38 , the second punch 70 is moved away from the metal workpiece 40.

[0185] 39, the first metal piece 47 is joined to the second metal piece 77. For example, the first metal piece 47 is welded to the second metal piece 77 by a weld 69. In this way, a metal part 2m is obtained.

[0186] (Variation)

[0187] The second tip 73 of the second punch 70 does not have to be rounded.

[0188] The metal part manufacturing apparatus 1m and the method for manufacturing a metal part 2m according to this embodiment have the following advantages in addition to the advantages of the metal part manufacturing apparatus 1 according to the first embodiment and the method for manufacturing a metal part 2k according to the eleventh embodiment.

[0189] The metal part manufacturing apparatus 1m of this embodiment further includes a second punch 70. The second punch 70 includes a second tip 73 and a second inclined surface 74. The second inclined surface 74 is connected to the second tip 73. The second inclined surface 74 is inclined toward the same side as the first inclined surface 14 (see FIGS. 3 to 8) with respect to the outer surface 71 or the inner surface 72. The outer diameter of the second punch 70 is smaller than the outer diameter of the first punch 10, and the inner diameter of the second punch 70 is smaller than the inner diameter of the first punch 10.

[0190] In the manufacturing method of the metal part 2m of this embodiment, closing the opening of the deep groove 48 includes splitting the first metal portion 46 into the second metal portion 76 and the second metal piece 77 while moving the second tip 73 of the second punch 70 from the end face 43 into the inside of the first metal portion 46, bringing the second metal piece 77 into contact with the first metal piece 47 that is in contact with the guide member 20 while moving the second tip 73 of the second punch 70 from the end face 43 into the inside of the first metal portion 46, and guiding the second metal piece 77 by the first metal piece 47, and joining the first metal piece 47 to the second metal piece 77.

[0191] Therefore, without using the sealing member 66 and the lid 67 of the eleventh embodiment, the opening of the deep groove 48 can be closed using the second punch 70 to form the cavity 68 in the metal workpiece 40. This reduces the cost of the metal part 2m.

[0192] Furthermore, when the second metal piece 77 is deformed by the first metal piece 47, the second metal piece 77 experiences deformation resistance from the first metal piece 47. Due to this deformation resistance, part of the metal material that constitutes the metal workpiece 40 accumulates in the part of the first metal portion 46 of the metal workpiece 40 that faces the second tip 73. Therefore, cracks that occur in the metal workpiece 40 can be prevented from occurring deeper than the second tip 73 of the second punch 70.

[0193] In the metal part manufacturing apparatus 1m of this embodiment, the second tip 73 of the second punch 70 is a rounded tip.

[0194] This reduces the concentration of the load applied to the metal workpiece 40 at the second tip 73 of the second punch 70. This prevents cracks from occurring in the metal workpiece 40 that are deeper than the second tip 73 of the second punch 70.

[0195] Embodiment 13

[0196] 40 to 42, a metal part manufacturing apparatus 1n according to a thirteenth embodiment will be described. The metal part manufacturing apparatus 1n according to the present embodiment has a configuration similar to that of the metal part manufacturing apparatus 1i according to the ninth embodiment, but differs from the metal part manufacturing apparatus 1i according to the ninth embodiment in that it further includes the second punch 70 according to the twelfth embodiment.

[0197] 40 to 42, a method for manufacturing a metal part 2n according to embodiment 13 using a metal part manufacturing apparatus 1n will be described. The method for manufacturing a metal part 2n according to this embodiment includes the same steps as the method for manufacturing a metal part 2i according to embodiment 9, but differs from the method for manufacturing a metal part 2i according to embodiment 9 in the following respects.

[0198] 42, the metal part 2n is configured similarly to the metal part 2m of the twelfth embodiment, but differs from the metal part 2m of the twelfth embodiment in that the first metal piece 47 is crimped to the second metal piece 77. That is, by crimping the first metal piece 47 to the second metal piece 77, the opening of the deep groove 48 is closed, and the deep groove 48 becomes a cavity 68.

[0199] 40 and 41, the method for manufacturing the metal part 2n of this embodiment follows the method for manufacturing the metal part 2i of embodiment 9 (see FIGS. 26 to 31), and further includes closing the opening of the deep groove 48 to form a cavity 68 in the metal workpiece 40, similar to the method for manufacturing the metal part 2m of embodiment 12. As shown in FIG. 42, the method for manufacturing the metal part 2n of this embodiment further includes crimping the first metal piece 47 to the second metal piece 77. In this way, the metal part 2n is obtained.

[0200] The metal part manufacturing apparatus 1n and the method for manufacturing a metal part 2n according to the present embodiment have the following advantages in addition to the advantages of the metal part manufacturing apparatus 1i according to the ninth embodiment and the method for manufacturing a metal part 2m according to the twelfth embodiment.

[0201] The metal part manufacturing apparatus In of this embodiment further includes a second punch 70. The second punch 70 includes a second tip 73 and a second inclined surface 74. The second inclined surface 74 is connected to the second tip 73. The second inclined surface 74 is inclined toward the same side as the first inclined surface 14 (see FIGS. 3 to 8) with respect to the outer surface 71 or the inner surface 72. The outer diameter of the second punch 70 is smaller than the outer diameter of the first punch 10, and the inner diameter of the second punch 70 is smaller than the inner diameter of the first punch 10.

[0202] In the manufacturing method of the metal part 2n of this embodiment, closing the opening of the deep groove 48 includes splitting the first metal part 46 into the second metal part 76 and the second metal piece 77 while moving the second tip 73 of the second punch 70 from the end face 43 into the inside of the first metal part 46, bringing the second metal piece 77 into contact with the first metal piece 47 that is in contact with the guide member 20 while moving the second tip 73 of the second punch 70 from the end face 43 into the inside of the first metal part 46, and guiding the second metal piece 77 by the first metal piece 47, and crimping the first metal piece 47 to the second metal piece 77.

[0203] Therefore, the cavity 68 can be formed in the metal workpiece 40 by crimping the first metal piece 47 to the second metal piece 77 without welding or bonding the first metal piece 47 to the second metal piece 77. This further reduces the cost of the metal part 2n.

[0204] Embodiment 14

[0205] 43 to 45, a metal part manufacturing apparatus 1p according to embodiment 14 will be described. The metal part manufacturing apparatus 1p of this embodiment has a configuration similar to that of the metal part manufacturing apparatus 1 of embodiment 1, but differs from the metal part manufacturing apparatus 1 of embodiment 1 in the following respects.

[0206] The metal part manufacturing apparatus 1p further includes a support tool 32 and a necking die 35. The necking die 35 is a press tool that deforms the tip portion of the first metal piece 47. The support tool 32 supports the base portion of the first metal piece 47 that is connected to the metal workpiece 40. Therefore, while the tip portion of the metal piece is being deformed using the necking die 35, the base portion of the first metal piece 47 is prevented from being significantly deformed.

[0207] As shown in FIG. 45 , the metal part 2p is a metal tube 40a having a cavity 68 formed in the outer surface 41, similar to the metal part 2k of the eleventh embodiment. The cavity 68 is defined by a first metal portion 46 and a first metal piece 47. In the metal part 2p, the tip of the first metal piece 47 is joined to the first metal part 46 to close the opening of the deep groove 48. In this way, the deep groove 48 becomes the cavity 68. The tip of the first metal piece 47 is welded to the first metal part 46 by, for example, a weld 69. The tip of the first metal piece 47 may also be adhered to the first metal part 46 by an adhesive.

[0208] 43 to 45, the method for manufacturing the metal part 2p of the present embodiment, following the method for manufacturing the metal part 2 of embodiment 1 (see FIGS. 5 to 8), further includes closing the openings of the deep grooves 48 to form cavities 68 in the metal workpiece 40. In the method for manufacturing the metal part 2p of the present embodiment, closing the openings of the deep grooves 48 includes the following steps.

[0209] As shown in Figures 43 and 44, the first metal piece 47 is metal-machined. Specifically, the base portion of the first metal piece 47 is supported by the support tool 32. The tip portion of the first metal piece 47 is deformed using the nozzle die 35. The tip portion of the first metal piece 47 is brought into contact with the first metal portion 46. While the tip portion of the metal piece is being deformed using the nozzle die 35, the support tool 32 prevents the base portion of the first metal piece 47 from being significantly deformed. The nozzle die 35 is moved away from the metal workpiece 40. The support tool 32 is moved away from the metal workpiece 40.

[0210] 39, the first metal piece 47 is joined to the first metal portion 46. For example, the first metal piece 47 is welded to the first metal portion 46 by a weld 69. The first metal piece 47 may be adhered to the first metal portion 46 by an adhesive. In this way, the metal part 2p is obtained.

[0211] The metal part manufacturing apparatus 1p and the method for manufacturing a metal part 2p according to the present embodiment have the following advantages in addition to the advantages of the metal part manufacturing apparatus 1 according to the first embodiment and the method for manufacturing a metal part 2m according to the twelfth embodiment.

[0212] The metal part manufacturing apparatus 1 p further includes a necking die 35 and a support tool 32 .

[0213] In the manufacturing method of the metal part 2p of this embodiment, closing the opening of the deep groove 48 includes bringing the first metal piece 47 into contact with the first metal portion 46 by metal processing the first metal piece 47, and joining the first metal piece 47 to the first metal portion 46.

[0214] This allows the thickness of the first metal portion 46 to be increased, thereby improving the mechanical strength of the first metal portion 46. Furthermore, the opening of the deep groove 48 can be closed without using a punch (for example, the second punch 70 (see FIGS. 37 and 38)), thereby reducing breakage and wear of the punch.

[0215] Embodiment 15

[0216] A metal part 2q according to embodiment 15 will be described with reference to Fig. 46. The metal part 2q according to this embodiment has a similar configuration to the metal part 2k according to embodiment 11 (see Fig. 35), but differs from the metal part 2k according to embodiment 11 in the following respects.

[0217] The metal part 2q further includes pipes 79a and 79b. In the metal part 2q, the first metal piece 47 is provided with through holes 47e and 47f that communicate with the cavity 68. The pipe 79a is connected to the first metal piece 47 and communicates with the through hole 47e. The pipe 79b is connected to the first metal piece 47 and communicates with the through hole 47f. Therefore, a fluid such as a liquid or gas can be supplied to the cavity 68 through the pipe 79a, and the fluid can be discharged from the cavity 68 through the pipe 79b. The metal part 2q can be efficiently heated, cooled, or kept warm by the fluid.

[0218] A method for manufacturing the metal part 2q of the embodiment 15 will be described. The method for manufacturing the metal part 2q of the embodiment 15 includes the following steps subsequent to the method for manufacturing the metal part 2k of the embodiment 11.

[0219] Through holes 47e and 47f are formed in the first metal piece 47. The through holes 47e and 47f are connected to the cavity 68. Then, pipes 79a and 79b are connected to the first metal piece 47. The pipes 79a and 79b are, for example, welded or bonded to the first metal piece 47. The pipe 79a is connected to the through hole 47e. The pipe 79b is connected to the through hole 47f. In this way, the metal part 2q is obtained.

[0220] (Variation)

[0221] A metal part 2r according to a modification of this embodiment will be described with reference to FIG. 47. The metal part 2r according to this modification has a configuration similar to that of the metal part 2p according to embodiment 14 (see FIG. 45), but differs from the metal part 2p according to embodiment 14 in the following respects. The metal part 2r further includes pipes 79a and 79b, similar to the metal part 2q according to this embodiment (see FIG. 46). The metal part 2r has through holes 47e and 47f formed in the first metal piece 47, similar to the metal part 2q according to this embodiment. The pipes 79a and 79b are connected to the first metal piece 47. The pipe 79a is in communication with the through hole 47e. The pipe 79b is in communication with the through hole 47f.

[0222] The manufacturing method of metal part 2r of a modified example of this embodiment follows the manufacturing method of metal part 2p of embodiment 14, and further includes forming through holes 47e, 47f in first metal piece 47 and connecting pipes 79a, 79b to first metal piece 47, similar to the manufacturing method of metal part 2q of this embodiment.

[0223] The method for manufacturing the metal parts 2q, 2r of this embodiment has the following advantages in addition to the advantages of the methods for manufacturing the metal parts 2 of the eleventh and fourteenth embodiments.

[0224] The manufacturing method for the metal parts 2q, 2r of this embodiment further includes forming through holes 47e, 47f in the first metal piece 47 that communicate with the cavity 68, and connecting pipes 79a, 79b that communicate with the through holes 47e, 47f to the first metal piece 47. The metal workpiece 40 is a hollow metal workpiece. The deep grooves 48 and the cavities are formed in the outer surface 41 of the hollow metal workpiece.

[0225] Therefore, a fluid such as a liquid or gas can be supplied to or discharged from the cavity 68 through the pipes 79a and 79b. A metal part 2q that can be efficiently heated, cooled, or kept warm by the fluid can be manufactured.

[0226] Embodiment 16

[0227] A motor 80 according to a sixteenth embodiment will be described with reference to Fig. 48. The motor 80 includes a stator frame 81, pipes 88a and 88b, bearings 90 and 97, a stator core 91, a rotor 92, and a bracket 96.

[0228] The stator frame 81 is made of metal. The stator frame 81 includes a bottom plate 82 and a side wall 83 connected to the bottom plate 82. The bottom plate 82 and the side wall 83 define an accommodation space 86. The stator frame 81 is, for example, a drawn product in which a cavity 87 is formed on the outer surface of the side wall 83. The side wall 83 includes a metal portion 84 and a metal piece 85. The cavity 87 is defined by the metal portion 84 and the metal piece 85. As in the modified example of the fifteenth embodiment (see FIG. 47), the tip of the metal piece 85 is joined to the metal portion 84. The metal piece 85 has through holes 85a and 85b that communicate with the cavity 87.

[0229] The pipe 88a is connected to the metal piece 85 and communicates with the through-hole 85a of the metal piece 85. The pipe 88b is connected to the metal piece 85 and communicates with the through-hole 85b of the metal piece 85. Therefore, a liquid such as water can be supplied to the cavity 87 through the pipe 88a, and the liquid can be discharged from the cavity 87 through the pipe 88b. The stator frame 81 can be cooled by the liquid.

[0230] The bracket 96 is fixed to the stator frame 81. The bracket 96 closes the upper opening of the stator frame 81.

[0231] The stator core 91 is disposed in the accommodation space 86. The stator core 91 has, for example, a cylindrical shape.

[0232] The rotor 92 includes a rotor shaft 93 and a rotor core 94. The rotor shaft 93 is inserted into a hole provided in the bottom plate 82 and a hole provided in the bracket 96. The rotor core 94 is fixed to the rotor shaft 93. The rotor core 94 is disposed in the accommodation space 86. The rotor core 94 faces the stator core 91.

[0233] The bearing 90 is disposed within the accommodation space 86. The bearing 90 is disposed on, for example, the bottom plate 82. The bearing 97 is fixed to the bracket 96. The bearings 90 and 97 rotatably support the rotor. Specifically, the bearings 90 and 97 rotatably support the rotor shaft 93.

[0234] A method for manufacturing the motor 80 of the sixteenth embodiment will be described with reference to FIGS.

[0235] A stator frame 81 is formed (S1). For example, a cavity 87 is formed on the outer surface of the drawn product 40b of the second embodiment by a method similar to that used to manufacture the metal part 2p of the fourteenth embodiment. Then, through holes 85a, 85b are formed in the metal piece 85 by a method similar to that used to manufacture the metal part 2r of the fifteenth embodiment. Pipes 88a, 88b are connected to the metal piece 85 by a method similar to that used to manufacture the metal part 2r of the fifteenth embodiment. In this way, the stator frame 81 is obtained.

[0236] A bearing 90 is installed in the stator frame 81 (S2). For example, the bearing 90 is placed on the bottom plate 82 of the stator frame 81. A stator core 91 is placed in the stator frame 81 (S3). A bearing 97 is installed in the bracket 96 (S4).

[0237] The rotor 92 is assembled (S5). Specifically, the rotor shaft 93 is fitted into the inner ring of the bearing 90 and the inner ring of the bearing 97. The rotor core 94 faces the stator core 91 inside the stator frame 81. The bracket 96 is attached to the stator frame 81 (S6). The bracket 96 closes the upper opening of the stator frame 81. In this way, the motor 80 is obtained.

[0238] The method for manufacturing the motor 80 of this embodiment has the following advantages in addition to the advantages of the method for manufacturing the metal part 2r of the modified example of the fifteenth embodiment.

[0239] The manufacturing method of motor 80 of this embodiment includes forming a stator frame 81 by the manufacturing method of metal part 2r of a modified example of embodiment 15, placing a stator core 91 in stator frame 81, and assembling a rotor 92 including a rotor core 94 facing stator core 91 within stator frame 81.

[0240] Therefore, it is possible to obtain a motor 80 including a stator frame 81 in which deep grooves with a controlled shape are formed. Also, it is possible to reduce the manufacturing cost of the stator frame 81. Liquid can be supplied to or discharged from the cavity 87 through the pipes 88a and 88b. The motor 80 can be efficiently cooled by the liquid.

[0241] Various aspects of the present disclosure are summarized below as appendices.

[0242] (Appendix 1) a first punch including a first tip; a guide member disposed opposite the first portion of the metal workpiece with a gap therebetween, the metal workpiece includes an end surface, and the first portion of the metal workpiece includes the end surface; While moving the first tip of the first punch from the end surface of the metal workpiece to the inside of the metal workpiece, the first portion of the metal workpiece is split into a first metal portion and a first metal piece, thereby forming a deep groove on the end surface of the metal workpiece, and the deep groove is formed between the first metal portion and the first metal piece; A metal part manufacturing apparatus, wherein the guide member contacts and guides the first metal piece while the first tip of the first punch is moved from the end surface of the metal workpiece to the interior of the metal workpiece. (Appendix 2) 2. The metal part manufacturing apparatus of claim 1, wherein the first tip is a rounded tip. (Appendix 3) the first punch includes a first inclined surface connected to the first tip and inclined so as to move away from the metal workpiece as it moves away from the first tip, 3. The metal part manufacturing apparatus according to claim 1, wherein the first inclined surface guides the first metal piece toward the guide member. (Appendix 4) 4. The metal part manufacturing apparatus of claim 3, wherein the first punch includes a second inclined surface connected to the first tip and inclined opposite the first inclined surface. (Appendix 5) the guide member includes a protrusion that protrudes from a tip end of the guide member toward a side closer to the first punch with respect to the guide member, 5. The metal part manufacturing apparatus according to claim 1, wherein the first metal piece is ironed by the protrusion of the guide member by moving the guide member relative to the metal workpiece. (Appendix 6) A metal part manufacturing apparatus according to any one of claims 1 to 5, wherein the cross-sectional shape of the first punch and the cross-sectional shape of the guide member are each the same as or partially the same as the cross-sectional shape of the metal workpiece. (Appendix 7) 7. The metal part manufacturing apparatus according to claim 1, further comprising a fixing member for fixing the metal workpiece. (Appendix 8) a guide member disposed opposite a first portion of a metal workpiece with a gap therebetween, the metal workpiece including an end surface, the first portion of the metal workpiece including the end surface; forming a deep groove in the end surface of the metal workpiece using a first punch including a first tip, wherein forming the deep groove includes splitting the first portion of the metal workpiece into a first metal portion and a first metal piece while moving the first tip of the first punch from the end surface of the metal workpiece to the inside of the metal workpiece, and the deep groove is formed between the first metal portion and the first metal piece; A method for manufacturing a metal part, comprising contacting the first metal piece with the guide member and guiding the first metal piece with the guide member while moving the first tip of the first punch from the end face of the metal workpiece to the interior of the metal workpiece. (Appendix 9) 9. The method for manufacturing a metal part according to claim 8, wherein the first tip is a rounded tip. (Appendix 10) and further comprising guiding the first metal piece toward the guide member by a first inclined surface of the first punch. 10. The method for manufacturing a metal part according to claim 8 or 9, wherein the first inclined surface is connected to the first tip of the first punch and is inclined so as to move away from the metal workpiece as it moves away from the first tip. (Appendix 11) 11. A method for manufacturing a metal part as described in Appendix 10, wherein the first punch includes a second inclined surface connected to the first tip and inclined opposite to the first inclined surface. (Appendix 12) The guide member is moved relative to the metal workpiece, and the first metal piece is ironed with a protrusion of the guide member. A method for manufacturing a metal part according to any one of claims 8 to 11, wherein the protrusion protrudes from the tip of the guide member on a side closer to the first punch relative to the guide member. (Appendix 13) A method for manufacturing a metal part described in any one of Appendix 8 to Appendix 12, wherein the cross-sectional shape of the first punch and the cross-sectional shape of the guide member are each the same as or partially the same as the cross-sectional shape of the metal workpiece. (Appendix 14) 14. The method for manufacturing a metal part according to any one of claims 8 to 13, further comprising closing an opening of the deep groove to form a cavity in the metal workpiece. (Appendix 15) 15. The method for manufacturing a metal part according to claim 14, wherein closing the opening of the deep groove includes fitting a sealing member into the opening of the deep groove. (Appendix 16) 15. The method for manufacturing a metal part described in Appendix 14, wherein closing the opening of the deep groove includes fitting a lid into the opening of the deep groove and joining or crimping the lid to the first metal portion and the first metal piece. (Appendix 17) Closing the opening of the deep groove includes: splitting the first metal portion into a second metal portion and a second metal piece while moving a second tip of a second punch from the end surface into the inside of the first metal portion; while moving the second tip of the second punch from the end surface to the inside of the first metal portion, bringing the second metal piece into contact with the first metal piece that is in contact with the guide member, and guiding the second metal piece by the first metal piece; and joining or caulking the first metal piece to the second metal piece. (Appendix 18) 18. The method for manufacturing a metal part according to claim 17, wherein the second tip is a rounded tip. (Appendix 19) 15. The method for manufacturing a metal part described in Appendix 14, wherein closing the opening of the deep groove includes metal processing the first metal piece to bring the first metal piece into contact with the first metal portion, and joining the first metal piece to the first metal portion. (Appendix 20) forming a through hole in the first metal piece that communicates with the cavity; a pipe communicating with the through hole is connected to the first metal piece; the metal workpiece is a hollow metal workpiece; A method for manufacturing a metal part described in any one of Appendix 14 to Appendix 19, wherein the deep groove and the cavity are formed on the outer surface of the hollow metal workpiece. (Appendix 21) forming a stator frame by the method for manufacturing the metal part described in Appendix 20; disposing a stator core within the stator frame; and assembling a rotor including a rotor core facing the stator core within the stator frame. (Appendix 22) 22. The method for manufacturing a metal part according to any one of appendix 8 to appendix 21, wherein the metal workpiece is a metal pipe, a metal bar, a drawn product drawn from a metal plate, or a burred product formed by stretch flange processing.

[0243] The presently disclosed embodiments 1-16 and their modifications should be considered to be illustrative in all respects and not restrictive. Unless there is a contradiction, at least two of the presently disclosed embodiments 1-16 and their modifications may be combined. The scope of the present disclosure is defined by the claims, not the above description, and is intended to include all modifications within the meaning and scope of the claims. [Explanation of symbols]

[0244] 1, 1e, 1f, 1g, 1i, 1j, 1m, 1n, 1p Metal part manufacturing apparatus, 2, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2k, 2l, 2m, 2n, 2p, 2q, 2r Metal part, 10 First punch, 11, 41 Outer surface, 12, 42 Inner surface, 13 First tip, 14 First inclined surface, 15 Second inclined surface, 20 Guide member, 21 First guide member, 22 Second guide member, 23 Protrusion, 29 Controller, 30 Fixing member, 32 Support tool, 35 Nozzle die, 40 Metal workpiece, 40a Metal tube, 40b Drawn product, 40c Burred product, 40d Metal bar, 40f Part, 43, 44 End surface, 46 First metal part, 46b, 76 Second metal part, 47 First metal piece, 47b, 57, 77 Second metal piece, 47e, 47f Through hole, 48, 48b, 58 Deep groove, 51 Bottom plate, 52 Side wall, 54 Pipe portion, 55 Flange portion, 60, 70 Second punch, 61, 71 Outer surface, 62, 72 Inner surface, 63, 73 Second tip, 64, 74 Second inclined surface, 66 Sealing member, 67 Lid, 67a Base portion, 67b Protrusion, 68 Cavity, 69, 69a, 69b Welded portion, 79a, 79b Pipe, 80 Motor, 81 Stator frame, 82 Bottom plate, 83 Side wall, 84 Metal portion, 85 Metal piece, 85a, 85b Through hole, 86 Storage space, 87 Cavity, 88a, 88b Pipe, 90, 97 Bearing, 91 Stator core, 92 rotor, 93 rotor shaft, 94 rotor core, 96 bracket.

Claims

1. a first punch including a first tip and a first inclined surface connected to the first tip and inclined so as to move away from the metal workpiece as it moves away from the first tip; a guide member disposed opposite the first portion of the metal workpiece with a gap therebetween, the metal workpiece includes an end surface, and the first portion of the metal workpiece includes the end surface; a deep groove is formed on the end surface of the metal workpiece by splitting the first portion of the metal workpiece into a first metal portion and a first metal piece while moving the first tip of the first punch from the end surface of the metal workpiece to the inside of the metal workpiece, and the deep groove is formed between the first metal portion and the first metal piece; A metal part manufacturing apparatus, wherein while the first tip of the first punch is moved from the end face of the metal workpiece to the interior of the metal workpiece, the first inclined surface guides the first metal piece toward the guide member, and the guide member contacts the first metal piece guided along the first inclined surface to guide the first metal piece.

2. The metal part manufacturing apparatus of claim 1 , wherein the first tip is a rounded tip.

3. 3. The metal part manufacturing apparatus according to claim 1, wherein the first punch includes a second inclined surface connected to the first tip and inclined in a direction opposite to the first inclined surface.

4. A first punch including a first tip; a guide member disposed opposite the first portion of the metal workpiece with a gap therebetween, the metal workpiece includes an end surface, and the first portion of the metal workpiece includes the end surface; a deep groove is formed on the end surface of the metal workpiece by splitting the first portion of the metal workpiece into a first metal portion and a first metal piece while moving the first tip of the first punch from the end surface of the metal workpiece to the inside of the metal workpiece, and the deep groove is formed between the first metal portion and the first metal piece; While the first tip of the first punch is moved from the end surface of the metal workpiece to the interior of the metal workpiece, the guide member contacts the first metal piece and guides the first metal piece; the guide member includes a protrusion that protrudes from a tip end of the guide member toward a side closer to the first punch with respect to the guide member, The metal part manufacturing apparatus comprises: a guide member that is moved relative to the metal workpiece, and the first metal piece is ironed by the protrusion of the guide member;

5. 5. The metal part manufacturing apparatus according to claim 1, wherein the cross-sectional shape of the first punch and the cross-sectional shape of the guide member are the same as or partially the same as the cross-sectional shape of the metal workpiece.

6. The metal part manufacturing apparatus according to claim 1 or 4, further comprising a fixing member for fixing the metal workpiece.

7. a guide member disposed opposite a first portion of a metal workpiece with a gap therebetween, the metal workpiece including an end surface, and the first portion of the metal workpiece including the end surface; forming a deep groove in the end surface of the metal workpiece using a first punch including a first tip, wherein forming the deep groove includes splitting the first portion of the metal workpiece into a first metal portion and a first metal piece while moving the first tip of the first punch from the end surface of the metal workpiece to the interior of the metal workpiece, and the deep groove is formed between the first metal portion and the first metal piece; While the first tip of the first punch is moving from the end surface of the metal workpiece to the inside of the metal workpiece, the first metal piece is guided toward the guide member by a first inclined surface of the first punch, and the first metal piece guided along the first inclined surface is brought into contact with the guide member, thereby guiding the first metal piece by the guide member, A method for manufacturing a metal part, wherein the first inclined surface is connected to the first tip of the first punch and is inclined so as to move away from the metal workpiece as it moves away from the first tip.

8. The method for manufacturing a metal part according to claim 7 , wherein the first tip is a rounded tip.

9. 9. The method for manufacturing a metal part according to claim 7 or 8, wherein the first punch includes a second inclined surface connected to the first tip and inclined in a direction opposite to the first inclined surface.

10. A method for manufacturing a metal workpiece, comprising: arranging a guide member opposite a first portion of the metal workpiece with a gap therebetween, the metal workpiece including an end surface, and the first portion of the metal workpiece including the end surface; forming a deep groove in the end surface of the metal workpiece using a first punch including a first tip, wherein forming the deep groove includes splitting the first portion of the metal workpiece into a first metal portion and a first metal piece while moving the first tip of the first punch from the end surface of the metal workpiece to the interior of the metal workpiece, and the deep groove is formed between the first metal portion and the first metal piece; While the first tip of the first punch is moving from the end surface of the metal workpiece to the interior of the metal workpiece, the first metal piece is brought into contact with the guide member, and the first metal piece is guided by the guide member; The method further comprises: moving the guide member relative to the metal workpiece and ironing the first metal piece with a protrusion of the guide member; The method for manufacturing a metal part, wherein the protrusion protrudes from the tip of the guide member toward a side of the guide member closer to the first punch.

11. 11. The method for manufacturing a metal part according to claim 7 or 10, wherein the cross-sectional shapes of the first punch and the guide member are the same as or partially the same as the cross-sectional shape of the metal workpiece.

12. The method comprises arranging a guide member opposite a first portion of a metal workpiece with a gap therebetween, the metal workpiece including an end face, and the first portion of the metal workpiece including the end face; forming a deep groove in the end surface of the metal workpiece using a first punch including a first tip, wherein forming the deep groove includes splitting the first portion of the metal workpiece into a first metal portion and a first metal piece while moving the first tip of the first punch from the end surface of the metal workpiece to the interior of the metal workpiece, and the deep groove is formed between the first metal portion and the first metal piece; While the first tip of the first punch is moving from the end surface of the metal workpiece to the interior of the metal workpiece, the first metal piece is brought into contact with the guide member, and the first metal piece is guided by the guide member; and closing the opening of the deep groove to form a cavity in the metal workpiece.

13. The method for manufacturing a metal part according to claim 12 , wherein closing the opening of the deep groove includes fitting a sealing member into the opening of the deep groove.

14. 13. The method for manufacturing a metal part according to claim 12, wherein closing the opening of the deep groove includes fitting a lid into the opening of the deep groove and joining or crimping the lid to the first metal portion and the first metal piece.

15. Closing the opening of the deep groove includes: splitting the first metal portion into a second metal portion and a second metal piece while moving a second tip of a second punch from the end surface into an interior of the first metal portion; while moving the second tip of the second punch from the end surface to the inside of the first metal portion, bringing the second metal piece into contact with the first metal piece that is in contact with the guide member, and guiding the second metal piece by the first metal piece; and joining or crimping the first metal piece to the second metal piece.

16. The method for manufacturing a metal part according to claim 15, wherein the second tip is a rounded tip.

17. 13. The method for manufacturing a metal part according to claim 12, wherein closing the opening of the deep groove includes contacting the first metal piece with the first metal portion by metal processing the first metal piece, and joining the first metal piece to the first metal portion.

18. forming a through hole in the first metal piece that communicates with the cavity; a pipe communicating with the through hole is connected to the first metal piece; the metal workpiece is a hollow metal workpiece; The method for manufacturing a metal part according to claim 12, wherein the grooves and the cavities are formed in an outer surface of the hollow metal workpiece.

19. forming a stator frame by the method for manufacturing a metal part according to claim 18; disposing a stator core within the stator frame; and assembling a rotor including a rotor core facing the stator core within the stator frame.

20. The method for manufacturing a metal part according to claim 7, claim 10 or claim 12, wherein the metal workpiece is a metal pipe, a metal bar, a drawn product formed by drawing a metal plate, or a burred product formed by stretch flange processing.

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