J. Jpn. Inst. Light Met. 64(8): (2014)

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1 * ** ** Journal of The Japan Institute of Light Metals, Vol. 64, No. 8 (2014), The Japan Institute of Light Metals Deep drawing of square cup with airtight using developed blank of 1100 aluminum sheet Nobuo HATANAKA*, Shogo WAKI** and Takashi IIZUKA** In the production of cups or containers by conventional deep drawing, the limiting drawing ratio obtained during the first drawing is very minimal. Therefore, to make deep cups, redrawing or ironing in one or more subsequent stages is necessary. An innovative method of producing very deep cups by employing a developed blank was previously proposed. In this method, the drawing resistance of the blank is reduced drastically, and so deep cups can be obtained at the first drawing. However, the drawn cup has seams in the side wall. To make an airtight cup, the seams must be joined. In this study, a new method of forming deep cups by using the developed blank was investigated. The developed blank is drawn with a punch, and friction stir welding (FSW) is conducted simultaneously to join the seams formed in the side wall. A rotation probe is put on the flange contact point and friction heat is generated, thus joining the seam parts. The experimental results show that the production of a very deep and airtight cup in a single process can be successfully accomplished with this proposed method. (Received February 27, 2014 Accepted May 8, 2014) Keywords: deep drawing, square cup, friction stir welding, airtight, aluminum sheet , , * Naruto University of Education (Naruto-chou, Narutoshi, Tokushima ). nhatanaka@naruto-u.ac.jp ** Kyoto Institute of Technology (Kyoto-shi, Kyoto).

2 Fig e a Fig. 1 Schematic diagram of experimental set up. (a) Punch, (b) connecting bolt, (c) blank holder, (d) blank, (e) die, (f) tool, (g) hydraulic cylinder, (h) rotate system. Fig. 2 Tool configuration and dimension. c f Table 1 28 mm 31 mm 3 mm 1 mm d g b 80 mm/min Fig. 2 D=8 mm d=2 mm L=0.75 mm SKD mm 1500 rpm 80 mm/min mm A1100-O Table 2 F n σ ε σ=fε n r ε l =0.17 Fig. 3 r c W mm 1 mm 3 Table 1 Dimensions of punch and die. Punch Die Wide (mm) Radius of corner (mm) 3 3 Radius of shoulder (mm) 3 3 Table 2 Mechanical properties of material (A1100-O). Tensile strength (MPa) F (MPa) n r Vickers hardness (Hv)

3 J. JILM mm r c =21.2 mm 2. 3 Fig. 4(a) C D r d 24 mm 28 mm 1 mm Fig. 4(b) 30 mm ϕ8.5 r d 5 3. Fig. 3 Dimension of specimen. Fig. 4 Blank holder (r d =24, 25, 26, 27, 28 mm) C C C r c Fig. 5 Variation of r c with punch stroke. C r c C C Fig. 3 C r c 2 mm 40 mm C r c Fig. 5 C r c W r c C 10 mm r c r c r c 2 mm 10 mm r c C C C C C C C

4 軽金属 Fig. 6 Forming results without FSW. Fig. 8 Welding surfaces (rd=26 mm). Fig. 7 Appearance of forming products (rd=26 mm). る 点 C の移動量がフランジの幅 W によらずほぼ同じ量を 取るのは しわ抑え板の摩擦力がフランジ幅によってほとん ど変わらないためであると考えられる このように 点 C の 移動に及ぼすしわ抑えの方式および潤滑の影響は大きいと思 われるが 詳細な検討については今後の課題とする Fig. 6 は 成形品の外観を示す W=17 mm の成形品の継ぎ 目部には 明確な隙間が観察された また 隙間の幅はフ ランジ端部に近づくほど大きい これは Fig. 5 においてパ ンチストロークの増加に伴い rc の値が急激に減少するために 隙間が生じたと考えられる W=18 mm の成形品は 継ぎ目 部に隙間を生じることなく 良好な成形品を得ることがで きた 一方 W=19, 20 mm の場合には Fig. 5 からわかるよ うに rc の値が大きく 点 C より内側では フランジが強く圧 縮され 大きな絞り変形を受ける このため Fig. 6(c) およ び (d) の側壁部には ダイスに強く押付けられながら成形が 進行した傷跡が観察された Fig. 9 Welding cross sections (rd=26 mm) 接合特性に及ぼすフランジ幅の影響 接合特性に及ぼすフランジ幅の影響を検討するために 摩 擦攪拌ツール中心位置 rd を 26 mm 一定とし フランジ幅を W=17, 18, 19, 20 mm rc=24, 25.5, 26.9, 28.3 mm と 変 化 を さ せて実験を行った このとき 攪拌ツール中心 点 D と フランジ接触点 点 C の距離 rc rd は mm であ る 成形品の外観を Fig. 7 に ツール接触面 内面 を Fig. 8 に示す また 攪拌開始点から 20 mm 加工が進行した位 置 W=20 mm の場合のみ 10 mm 加工の進行した位置 にお ける継ぎ目部断面を Fig. 9 に示す W=17 mm rc rd= 2.0 mm の場合には Fig. 7(a) に示すよ うにフランジ部は接合されておらず Fig. 8(a) からフランジ 部裏面のショルダ接触面には ショルダが面に接触した痕跡

5 J. JILM が確認されるものの 継ぎ目部には大きな隙間が発生してい る また Fig. 9(a) に示す断面からも まったく接合できて いないことがわかる W=18 mm rc rd= 0.5 mm の場合には ショルダ接触面では良好に攪拌されているように見えるが 外観からは接合が不十分であり キッシングボンドと考えら れる溝状欠陥が観察された また 断面図からも接合が不完 全で 攪拌された材料は継ぎ目部の上を覆っているだけであ る W=19 mm rc rd=0.9 mm の場合には 外観から良好に 接合されていることが確認される ショルダ接触面には均一 なショルダの接触痕が確認でき 断面からも良好に接合され ていることが確認される W=20 mm rc rd=2.3 mm の場合 には パンチストローク 25 mm において壁割れが発生し 成 形は完了できなかった しかし 破断するまでのショルダ接 触面には均一な接触痕が確認され 断面も接合開始 10 mm の 位置であるが十分に接合されている これらの結果から パンチ中心からツール中心までの距 離 rd=26 mm の条件においては W=17 mm ではフランジ幅が 小さく ツールの位置において隣接するフランジが接触して おらず 隙間が大きいため接合できなかったと考えられる W=18 mm の場合には 通常の成形においては Fig. 6(b) のよう に良好に成形された しかし 攪拌ツールの挿入により 接 合面が離されて隙間が生じ 接合できなかったと考えられ る W=19 mm の場合には容器の成形 継ぎ目部の接合とも に良好な結果が得られた W=20 mm の場合には フランジ 幅が大きいため 成形に伴う絞り抵抗が大きく さらに材料 を攪拌しながらダイス穴向きに移動させるための荷重が加わ るため コーナ部の材料流動が減少し 成形体の直辺部と コーナ部のフランジ変形速度の差が大きくなり 大きなせん 断変形が生じ 壁割れが発生したと考えられる 3. 3 接合特性に及ぼす攪拌ツール位置の影響 攪拌ツールの位置が 成形および接合結果に及ぼす影響に ついて検討した 前節で成形および接合ともに良好な結果が 得られた フランジ幅 W=19 mm rc=26.9 mm の展開ブラン クを使用して ツール中心位置を rd=25, 26, 27 mm と変化さ せて検討した このとき 攪拌ツール中心 点 D とフラン ジ接触点 点 C の距離 rc rd は mm である 得 られた成形品の外観を Fig. 10 に ツール接触面 内面 を Fig. 11 に示す また 攪拌開始点から 20 mm 加工の進行した 位置における継ぎ目部断面を Fig. 12 に示す rd=25 mm rc rd=1.9 mm の場合には パンチストローク 30 mm において Fig. 10(a) に示すように壁割れが発生した し かし 外観から接合は比較的良好に行われたことがわかる Fig. 11(a) から ショルダ接触面にも比較的良好な接触痕が 確認でき Fig. 12(a) から断面も良好に接合されていること が確認できる rd=26 mm rc rd=0.9 mm の場合は 前節で Fig. 10 Appearance of forming products (rc=26.9 mm). Fig. 12 Welding cross sections (rc=26.9 mm). Fig. 11 Welding surfaces (rc=26.9 mm).

6 Table 3 Various forming results. Title (a) Good (b) 30 mm crack Symbol Appearance Title (c) Seaming failure (d) Clearance Symbol Fig. 13 Influence of forming results with width of flange. Appearance Title (e) Under 30 mm crack (f) Crack from punch corner Symbol Appearance W=19 mm r d =27 mm r c r d = 0.1 mm W=19 mm r c =26.9 mm r d =25 mm r c r d =26 mm r d =27 mm r c r d = 0.1 mm 3. 4 W r d Table 3 a 40 mm b 30 mm c d e 30 mm f W D C r c r d Fig. 13 Table 3 W=17 mm r c =24.0 mm Fig. 5 Fig. 6 r c 24 mm 22 mm W=18, 19, 20 mm r c r d 0 mm r c r c r d 2.0 mm W=18 20 mm, r c r d =0 2.0 mm W=19 mm, r c r d =0.9 mm W=18 mm, r c r d =1.5 mm r d 4. 1 W=17 mm 2 D r d C r c r c r d 0 3 W=18 20 mm 0<r c r d <2 mm 4 r c r d >2 mm

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