Method for manufacturing metal ring, and metal ring

Abstract

Provided is a method for manufacturing a metal ring. The method for manufacturing a metal ring comprises: fitting a second ring made of aluminum or an aluminum alloy into the inside of a first ring made of aluminum or an aluminum alloy; and forging a combined ring in which the second ring is fitted into the first ring. In the forging, the method alternately repeats: compressing, in the thickness direction, a portion of the combined ring in the circumferential direction by a compression device; and, after the compression, moving the combined ring relative to the compression device in the circumferential direction of the combined ring.

Description

METAL RING MANUFACTURING METHOD AND METAL RING CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This international application claims priority based on Japanese Patent Application No. 2023-174682, filed with the Japan Patent Office on October 6, 2023, the entire contents of which are incorporated herein by reference.

[0002] The present disclosure relates to a method for manufacturing a metal ring and a metal ring.

[0003] The following Patent Document 1 discloses a pressure welding method in which two metal rings are fitted together and then the outer peripheral surface of the inner metal ring is tightly attached to the inner peripheral surface of the outer metal ring by ring rolling.

[0004] Japanese Patent Application Laid-Open No. 2002-1461

[0005] The above-mentioned pressure welding method using ring rolling has a limit to the area to which pressure can be applied due to the structure of the equipment, so it is not possible to manufacture large-diameter, long, multi-layered metal rings.

[0006] One aspect of the present disclosure is to provide a method for manufacturing a metal ring, which can produce a metal ring having a large diameter and a long multi-layer structure.

[0007] One aspect of the present disclosure is a method for manufacturing a metal ring, comprising: fitting a second ring made of aluminum or an aluminum alloy inside a first ring made of aluminum or an aluminum alloy; and forging a combined ring in which the second ring is fitted into the first ring. The forging alternately involves compressing a portion of the combined ring in the thickness direction using a compression device, and then moving the combined ring relative to the compression device in the circumferential direction of the combined ring.

[0008] According to this configuration, by repeating the steps of partially compressing the combined ring and then changing the compressed portion, it is possible to forge a combined ring having a large diameter and a long length, thereby obtaining a metal ring having a large diameter and a long length with a multi-layer structure.

[0009] Fig. 1A is a schematic perspective view of a metal ring in this embodiment, and Fig. 1B is a schematic plan view of the metal ring of Fig. 1A. Fig. 2 is a flow chart of a method for manufacturing a metal ring in this embodiment. Fig. 3 is a schematic diagram showing the procedure of a fitting step in the method for manufacturing the metal ring of Fig. 2. Fig. 4A is a schematic side view of a compression device used in a forging step in the method for manufacturing the metal ring of Fig. 2, and Fig. 4B is a schematic front view of the compression device of Fig. 4A.

[0010] 100...metal ring, 101...first layer, 102...second layer, 103...third layer, 201...first ring, 202...second ring, 203...third ring, 210...combining ring, 300...compression device, 301...core material, 302...support part, 303...press part.

[0011] Hereinafter, embodiments to which the present disclosure is applied will be described with reference to the drawings.

[0012] 1. First Embodiment 1-1. Configuration Metal Ring 100 The metal ring 100 shown in FIGS. 1A and 1B is a clad material having a plurality of metal layers with different compositions.

[0013] Specifically, the metal ring 100 includes a first layer 101, a second layer 102, and a third layer 103. The first layer 101 constitutes the outermost layer of the metal ring 100. The second layer 102 is disposed inside the first layer 101. The third layer 103 is disposed inside the second layer 102.

[0014] The first layer 101, the second layer 102, and the third layer 103 are each made of aluminum or an aluminum alloy. An example of a combination of compositions of the first layer 101, the second layer 102, and the third layer 103 is a standard combination conforming to JIS-H-4000, in which the first layer 101 is made of A5052, the second layer 102 is made of A7050, and the third layer 103 is made of A6061.

[0015] The dimensions of the metal ring 100 are either within the following first or second range. In the first range, the outer diameter R is 300 mm or more and 3000 mm or less, and the length L is 200 mm or more and 1500 mm or less. In the second range, the outer diameter R is 300 mm or more and 1000 mm or less, and the length L is 200 mm or more and 3000 mm or less.

[0016] <Method for Manufacturing Metal Ring> The method for manufacturing a metal ring shown in Fig. 2 includes a fitting step S10 and a forging step S20. The metal ring 100 shown in Fig. 1A is obtained by the method for manufacturing a metal ring.

[0017] 3, in this step, the second ring 202 is fitted inside the first ring 201. In addition, the third ring 203 is fitted inside the second ring 202.

[0018] The first ring 201, the second ring 202, and the third ring 203 respectively form the first layer 101, the second layer 102, and the third layer 103 of the metal ring 100. That is, the first ring 201, the second ring 202, and the third ring 203 are made of aluminum or an aluminum alloy.

[0019] The thickness of the first ring 201 is greater than the thickness of the first layer 101. The thickness of the second ring 202 is greater than the thickness of the second layer 102. The thickness of the third ring 203 is greater than the thickness of the third layer 103.

[0020] Specifically, the second ring 202 at room temperature is first inserted inside the thermally expanded first ring 201, and the first ring 201 is then cooled, thereby shrink-fitting the second ring 202 onto the first ring 201.

[0021] Next, the third ring 203 at room temperature is inserted inside the thermally expanded first ring 201 and second ring 202, and the first ring 201 and second ring 202 are cooled, thereby shrink-fitting the third ring 203 onto the second ring 202.

[0022] The heating temperature of each ring during shrink fitting is, for example, 300° C. or higher and 450° C. or lower. By shrink fitting the second ring 202 and the third ring 203, a combined ring 210 (see FIG. 4B ) is obtained in which the first ring 201, the second ring 202, and the third ring 203 are integrated.

[0023] <Forging Step> In this step, a combined ring 210 is forged in which the second ring 202 is fitted into the first ring 201 and the third ring 203 is fitted into the second ring 202. This step includes a compression step S21 and a moving step S22.

[0024] 4A , in this step, a circumferential portion of the combined ring 210 is compressed in the thickness direction by a compression device 300. The compression device 300 has a core material 301, a support portion 302, and a press portion 303.

[0025] The core material 301 is a cylindrical member that is inserted into the hollow portion of the combined ring 210 in the axial direction of the combined ring 210. The length of the core material 301 is greater than the length of the combined ring 210. The core material 301 supports the combined ring 210 by abutting against the inner circumferential surface of the combined ring 210 from below.

[0026] The support portion 302 supports the core material 301 from below. The support portion 302 does not directly support the combining ring 210.

[0027] The press unit 303 is configured to be movable in the vertical direction and presses the combined ring 210 from the radially outer side (specifically, from above) of the combined ring 210 toward the core material 301 (specifically, downward).

[0028] The portion of the combined ring 210 pressed by the press portion 303 and the core material 301 is compressed in the thickness direction, thereby reducing the thickness of this portion and bringing the inner circumferential surface of the first ring 201 and the outer circumferential surface of the second ring 202, and the inner circumferential surface of the second ring 202 and the outer circumferential surface of the third ring 203 into pressure contact with each other.

[0029] <Moving Step> In this step, after the compressing step S21, the combining ring 210 is moved relative to the compressing device 300 in the circumferential direction of the combining ring 210.

[0030] Specifically, with the pressure from the press portion 303 released, the combined ring 210 is rotated circumferentially until the next part to be compressed is on the upper side (i.e., it reaches a position opposite the press portion 303).

[0031] In addition, the combined ring 210 may be rotated while the core material 301 is inserted into the combined ring 210, or the core material 301 may be removed from the combined ring 210, the combined ring 210 may be rotated, and then the core material 301 may be reinserted into the combined ring 210.

[0032] In the forging step S20, the compression step S21 and the moving step S22 are alternately repeated until the thickness of the combined ring 210 reaches the target thickness around the entire circumference. That is, multiple compression operations are performed on the same region of the combined ring 210. The ratio of the thickness of the combined ring 210 after the forging step S20 to the thickness of the combined ring 210 before the forging step S20 (i.e., the compression rate) is, for example, 10% or more and 50% or less.

[0033] It should be noted that the inner diameter of the combined ring 210 gradually increases as the compression step S21 is repeated. Therefore, the core material 301 may be replaced with one having a different outer diameter depending on the inner diameter of the combined ring 210 (i.e., the number of presses).

[0034] [1-2. Effects] According to the embodiment described above in detail, the following effects can be obtained.

[0035] (1a) By repeating the steps of partially compressing the combined ring 210 and then changing the compressed portion, it is possible to forge a large-diameter, long combined ring 210. As a result, a large-diameter, long metal ring 100 having a multi-layer structure can be obtained.

[0036] (1b) By fitting the second ring 202 into the first ring 201 by shrink fitting, the number of steps required to obtain the combined ring 210 can be reduced.

[0037] (1c) By rotating the combining ring 210 in the moving step S22, workability is improved compared to when the compression device 300 (i.e., the core material 301 and the press unit 303) is moved.

[0038] (1d) By using the compression device 300 having the core material 301 and the press section 303, it is possible to manufacture a large-diameter and long metal ring 100 using existing equipment.

[0039] [2. Other Embodiments] Although the embodiments of the present disclosure have been described above, it goes without saying that the present disclosure is not limited to the above-described embodiments and can take on various forms.

[0040] (2a) In the method for manufacturing a metal ring according to the above embodiment, the metal ring 100 may have a two-layer structure. That is, the metal ring 100 may include only the first layer 101 and the second layer 102. Alternatively, the metal ring 100 may have a structure of four or more layers. That is, the metal ring 100 may have an additional layer inside the third layer 103.

[0041] (2b) In the manufacturing method of the metal ring according to the above embodiment, in the fitting step, cold fitting may be used instead of shrink fitting. For example, the second ring 202, which has shrunk due to cooling, may be inserted inside the first ring 201, which is at room temperature, and the second ring 202 may be heated to fit the second ring 202 into the first ring 201.

[0042] (2c) In the manufacturing method of the metal ring of the above embodiment, in the moving step, instead of rotating the combined ring 210, a part of the compression device 300 (for example, the core material 301) may be moved relative to the combined ring 210.

[0043] (2d) The function of one component in the above embodiments may be distributed among multiple components, or the functions of multiple components may be integrated into one component. Furthermore, part of the configuration of the above embodiments may be omitted. Furthermore, at least part of the configuration of the above embodiments may be added to, replaced with, or the like, the configuration of another of the above embodiments. Note that all aspects included in the technical idea identified from the wording of this disclosure are embodiments of the present disclosure.

Claims

1. A method for manufacturing a metal ring, comprising: fitting a second ring made of aluminum or an aluminum alloy inside a first ring made of aluminum or an aluminum alloy; and forging a combined ring in which the second ring is fitted into the first ring, wherein the forging alternately compresses a portion of the circumferential direction of the combined ring in its thickness direction using a compression device, and, after the compression, moves the combined ring relatively in the circumferential direction of the combined ring with respect to the compression device.

2. A method for manufacturing a metal ring as described in claim 1, wherein the fitting step includes inserting the second ring inside the thermally expanded first ring, and then cooling the first ring.

3. A method for manufacturing a metal ring as described in claim 1, wherein the moving comprises rotating the combined ring in a circumferential direction.

4. A method for manufacturing a metal ring as described in any one of claims 1 to 3, wherein the compression device has a core material inserted into the combined ring, and a press section that presses the combined ring toward the core material from the radial outside of the combined ring.

5. A method for manufacturing a metal ring according to any one of claims 1 to 3, wherein the forging produces a metal ring having an outer diameter of 300 mm or more and 3,000 mm or less and a length of 200 mm or more and 1,500 mm or less, or an outer diameter of 300 mm or more and 1,000 mm or less and a length of 200 mm or more and 3,000 mm or less.

6. A metal ring comprising a first layer of aluminum or an aluminum alloy and a second layer of aluminum or an aluminum alloy disposed inside the first layer, and having an outer diameter of 300 mm or more and 3,000 mm or less and a length of 200 mm or more and 1,500 mm or less, or an outer diameter of 300 mm or more and 1,000 mm or less and a length of 200 mm or more and 3,000 mm or less.

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