ROLLING APPARATUS

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of the International Application No. PCT/JP2024/030147, filed on Aug. 26, 2024, which claims the benefit of foreign priority to Japanese Patent Application No. 2024-061032 filed on Apr. 4, 2024, the entire contents of each of which are hereby incorporated by reference.

TECHNICAL FIELD

The present invention relates to a rolling apparatus that is used mainly for rolling threads and is capable of correcting a relative position of a fixed flat die thereof and a moving flat die thereof.

BACKGROUND ART

A device such as a rolling-pressure monitoring device disclosed in Patent Literature 1 has conventionally been known which monitors rolling pressures applied to base materials and thereby determines whether or not rolling has been performed appropriately.

CITATION LIST

Patent Literature

Patent Literature 1: JP-A-2021-175576

SUMMARY OF THE INVENTION

Technical Problem

In a rolling apparatus, the relative positions of a fixed flat die and a moving flat die are required to be precise. Specifically, the plastic deformation mark formed on the fixed flat die side and the plastic deformation mark formed on the moving flat die side need to coincide with each other. In particular, in thread rolling, when these plastic deformation marks are misaligned, the rolled product may be of no value as a finished product.

Conventionally, the correction of the positions of the fixed flat die and the moving flat die has depended in large part on the skilled person, and even so, multiple tests have had to be repeatedly carried out many times.

Therefore, an object of the present invention is to provide a rolling apparatus which facilitates an easy correction of the relative positions of a fixed flat die thereof and a moving flat die thereof.

Solution to Problem

A rolling apparatus according to the present invention, which includes a fixed flat die fixed on a base table and having a fixed-side rolling-surface section, and a moving flat die disposed reciprocally movable along a rolling direction on the base table, the moving flat die having a moving-side rolling-surface section opposite, during rolling processing, to the fixed-side rolling-surface section, includes:

• • a top-dead-center position adjusting means configured to adjust a position of a top dead center of the moving flat die along the rolling direction by manual manipulation;
  • a test-movement control means configured to execute a control content for producing a test piece having both a fixed-side streak in a groove shape based on the fixed-side rolling-surface section and a moving-side streak in a groove shape based on the moving-side rolling-surface section, the fixed-side streak and the moving-side streak being formed in a base material to be the test piece by automatically controlling both a going movement of the moving flat die that moves from the position of the top dead center along the rolling direction by a predetermined movement amount so as to cause the base material to rotate a half turn and a return movement of the moving flat die that returns to the position of the top dead center;
  • a positional-deviation-amount inputting means configured to receive an inputted positional deviation amount of the moving-side streak with respect to an appropriate position of the moving-side streak in a direction along an axis of the test piece, the appropriate position being determined, in a front elevation view of the test piece, to be a position of the moving-side streak in a state in which a center line of the groove of the moving-side streak coincides with a virtual groove center line defined by extending a center line of the groove of the fixed-side streak; and
  • a correction-movement-amount calculation controlling means configured to execute a control content for calculating a distance of the moving flat die to an appropriate position of the top dead center as a correction movement amount of the moving flat die based on the inputted positional deviation amount;
  • in the rolling apparatus, at least one of the fixed flat die and the moving flat die is disposed and capable of being positionally converted along an opposing direction in which the fixed-side rolling-surface section is opposed to the moving-side rolling-surface section;
  • the rolling apparatus further includes:
  • an opposing-position adjusting means configured to adjust, by manual manipulation, a relative position between the fixed flat die and the moving flat die in the opposing direction;
  • an opposing-position detecting means configured to detect the relative position between the fixed flat die and the moving flat die in the opposing direction;
  • a bite inputting means configured to receive an inputted bite depth, in a radial direction of the test piece, of the fixed-side streak and the moving-side streak formed by the test-movement control means; and
  • an adjustment-value outputting means configured to output the correction movement amount calculated by the correction-movement-amount calculation controlling means, opposing position information based on the relative position, in the opposing direction, detected by the opposing-position detecting means, and the inputted bite depth received by the bite inputting means.

In such a configuration, first, streaks are formed in a base material in a required region by using the test-movement control means, thereby producing a test piece in which such streaks are composed of fixed-side streaks and moving-side streaks. Then a positional deviation amount between the fixed-side streaks and the moving-side streaks, both formed in the test piece, is inputted by using the positional-deviation-amount inputting means. Then the correction-movement-amount calculation controlling means is used to calculate a correction movement amount to a position of the moving flat die where the appropriate position can be obtained. The thus-calculated correction movement amount is output by the adjustment-value outputting means. Based on this correction movement amount, the top-dead-center position adjusting means is used to adjust the position of the top dead center of the moving flat die such that the position of the top dead center is made appropriate for causing the moving-side streaks to coincide with the fixed-side streaks. Note that, as to how the predetermined movement amount is set for causing the base material to rotate a half turn for forming both streaks, the present invention has proposed a configuration in which the base material is rotated approximately a half turn. Specifically, such a configuration may be one in which the base material is rotated a half turn, may be one in which the base material is rotated slightly more than a half turn to the extent which the streaks do not become unmeasurable due to excessive overlap of the streaks, or may be one in which the base material is rotated slightly less than a half turn to the extent which the streaks do not overlap each other. The configuration is preferably one in which the base material is rotated slightly less than a half turn to the extent which the streaks do not overlap each other. Further, the rotary direction of the base material may be either forward or reverse.

Further, the opposing-position adjusting means is used to adjust the relative position between the fixed flat die and the moving flat die in the opposing direction such that the relative position in the opposing direction is set so as to provide an appropriate bite depth, based on the bite depths of the fixed-side streaks and moving-side streaks which all have been formed in the test piece, and the opposing position information of the fixed flat die and the moving flat die when these fixed-side streaks and moving-side streaks are formed. Here, since the bite depth determines the thread pitch and the rolling pressure (the pressure caused by the fixed flat die and the moving flat die while rolling processing), pitch alignment of the thread and optimization of the rolling pressure can be performed by adjusting the bite depth appropriately. This allows pitch alignment with high precision, which results in a reduction in occurrence of pitch-forming defects, and also allows rolling processing with an appropriate rolling pressure, which results in a reduction in occurrence of slipping during the rolling processing, leading to a reduced occurrence of forming defects due to the slipping. By optimizing the bite depth in this way, the probability of occurrence of forming defects in the rolling processing (hereinafter referred to as forming defect rate) can be reduced.

In this way, in the configuration according to the present invention, based on the fixed-side streaks and moving-side streaks formed in the test piece, the position of the top dead center of the moving flat die is adjusted and the relative position between the moving flat die and the fixed flat die in the opposing direction is also adjusted, thereby increasing the rolling accuracy of threads and reducing the forming defect rate. Then, in this configuration, it is possible to adjust the position of the top dead center of the moving flat die in accordance with the correction movement amount, and also to adjust the relative position in the opposing direction by using the opposing position information and the bite depth. As a result, these adjustments can be performed without relying on the experience or intuition of an operator, and the burden required for the adjustment work can be reduced. Therefore, threads can be stably formed in compliance with the desired product standards with high precision, and the threads of excellent quality can be stably manufactured.

In the rolling apparatus described above according to the present invention, a configuration is proposed in which the adjustment-value outputting means may be configured to execute a control content for displaying the inputted bite depth received by the bite-depth inputting means on a predetermined display section, and a control content for sequentially displaying the opposing position information on the display section in accordance with the position adjustment of the moving flat die in the opposing direction by the opposing-position adjusting means.

In such a configuration, the opposing-position adjusting means may be used to adjust the relative position between the fixed flat die and the moving flat die in the opposing direction based on the bite depth and opposing position information displayed on the display section such that the relative position can be adjusted at a position that provides the desired bite depth. Thus, the relative position can be easily and stably adjusted at the position where the bite depth compliant with the desired product standards is achieved.

Note that, in the present configuration, the adjustment-value outputting means may be configured to include a correction position information calculating means to calculate a correction position information indicating the relative position in the opposing direction, which provides a desired bite depth, based on both the bite depth inputted by the bite-depth inputting means and the opposing position information when the fixed-side streaks and moving-side streaks are formed in the test piece. The adjustment-value outputting means may also be configured to execute a control content for displaying the thus-calculated correction position information on the display section.

According to this configuration, by operating the opposing-position adjusting means in accordance with the correction position information, the position adjustment can be performed more easily and stably for providing the desired bite depth.

In the rolling apparatus described above according to the present invention, a configuration is proposed in which the adjustment-value outputting means is configured to display a movement-amount corresponding graphic part on a predetermined display section, and in which the correction-movement-amount calculation controlling means is configured to execute a control content for producing the movement-amount corresponding graphic part in accordance with the movement amount in directions each orthogonal to the rolling direction of the moving flat die and the opposing direction in which the fixed-side rolling-surface section is opposed to the moving-side rolling-surface section, and a control content for causing the adjustment-value outputting means to display the produced movement-amount corresponding graphic part.

The movement-amount corresponding graphic part is displayed, for example, as a bar-shaped graphic extending to the right and left with the center as an appropriate position. How far the current position of the moving flat die is deviated from the appropriate position is suggested in the graphic, and an example of a mode is shown in which the graphic indicating the current position is adapted to coincide with the graphic indicating the appropriate position, by moving the moving flat die. This allows an operator to work extremely easily based on the visual information. Note that the movement-amount corresponding graphic part may take various forms.

Advantageous Effects of the Invention

The rolling apparatus of the present invention has the excellent effect of being able to easily correct the relative positions of the fixed flat die thereof and the moving flat die thereof.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a rolling apparatus 1 of an embodiment according to the present invention when viewed from the fixed flat die 3 side.

FIG. 2 is a perspective view of the rolling apparatus 1 when viewed from the moving flat die 4 side.

FIG. 3 is an enlarged plan view of the fixed flat die 3.

FIG. 4A and FIG. 4B are diagrams illustrating an aspect of forming fixed-side streaks 62 and moving-side streaks 63 in a base material 60.

FIG. 5A is a partly enlarged view of a test piece 61.

FIG. 5B is a partly enlarged cross-sectional view of the test piece 61.

FIG. 6 is a schematic diagram illustrating a position detecting device 35 that detects the positions of the fixed flat die 3 and the moving flat die 4.

FIG. 7A and FIG. 7B are diagrams illustrating an aspect of displaying a correction graphic part 81 on a touch panel 37.

FIG. 8 is a diagram illustrating an aspect of displaying a bite depth and opposing position information on the touch panel 37.

DESCRIPTION OF EMBODIMENTS

Embodiments of the present invention will be described with reference to examples. Note that the present invention is not limited to the examples described below, and the designs in the examples can be modified as appropriate.

As shown in FIGS. 1 and 2, a rolling apparatus 1 includes a base table 2. On the base table 2, there are disposed both a fixed flat die 3 having a fixed-side rolling-surface section 11 and a moving flat die 4 having a moving-side rolling-surface section 21. The moving flat die 4 is caused to go and return along the rolling direction. The moving flat die 4 is halted at a standby position before starting rolling while the rolling apparatus 1 is not in operation. The standby position is away from the fixed flat die 3 in the rolling direction, as specifically shown in FIGS. 1 and 2, and is different from a rolling start position (top dead center) to be described later.

In the description of the embodiment, the direction orthogonal to the rolling direction and in which the fixed-side rolling-surface section 11 faces the moving-side rolling-surface section 21, is referred to as the opposing direction (see FIGS. 1 and 2).

The fixed flat die 3 is fixed to a die block 25 by a clamping means (not shown). The die block 25 is fastened on the base table 2 with fastening bolts 10 and 10, and immovably fixed to the base table 2 together with the fixed flat die 3 while the fastening bolts 10 and 10 are being fastened.

The moving flat die 4 is disposed immovably in the up-and-down direction and the opposing direction while being reciprocally movable in the rolling direction through use of a guiding rail (not shown) disposed on the base table 2 along the rolling direction. On the base table 2, a drive controller (not shown) is disposed. The drive controller controls the reciprocal movement of the moving flat die 4.

The moving flat die 4 is halted, with respect to the fixed flat die 3, at the standby position located at one side in the rolling direction while the rolling apparatus 1 is not in operation as described above (FIGS. 1 and 2), and is moved to the top dead center to be described later before starting rolling (FIG. 4A). In the rolling processing, the moving flat die 4 is reciprocally moved starting from the top dead center along the rolling direction. After finishing the rolling processing, the moving flat die 4 returns to the standby position. Moreover, in the configuration of the embodiment, a correction bolt 8 is disposed (FIG. 2) for adjusting the position (position along the rolling direction) of the top dead center of the moving flat die 4. This allows the position of the top dead center of the moving flat die 4 to be adjustable along the rolling direction by rotating the correction bolt 8 forward or reverse.

In addition, in one side of the fixed flat die 3, a guide path section 19 is disposed for feeding a base material 60 between the fixed flat die 3 and the moving flat die 4. The rolling apparatus 1 according to the embodiment causes the base material 60 fed by the guide path section 19 to be compressed between the fixed-side rolling-surface section 11 of the fixed flat die 3 and the moving-side rolling-surface section 21 of the moving flat die 4, and causes the moving flat die 4 to reciprocally move in the rolling direction, thereby rolling processing the base material 60. The rolling apparatus 1 according to the embodiment forms male threads by rolling processing base materials having a substantially round bar shape.

In this embodiment, since known configurations are applicable to the configuration (the guiding rail, drive controller, etc.) for causing the moving flat die 4 to reciprocally move, the fixed-side rolling-surface section 11, and the moving-side rolling-surface section 21, the details thereof will be omitted.

Next, a principal part of the present invention will be described.

In the embodiment, as shown in FIGS. 1 and 2, the base table 2 includes a block-position reference section 26 to which the die block 25 is attached movably in the opposing direction. Then the die block 25 is movable in the opposing direction with respect to the block-position reference section 26 (base table 2) in the state of the fastening bolts 10, 10 being loosened. Thus, the die block 25 can be slid in the opposing direction while being in this state. With this configuration, the fixed flat die 3 and the die block 25 can be integrally moved in the opposing direction while the fixed flat die 3 is being fixed to the die block 25.

In the block-position reference section 26, position converting pull-out bolts 31, 31 are disposed at respective portions close to both ends of the block-position reference section 26 in the rolling direction. Further, at each portion closer to the respective ends than the respective position converting pull-out bolts 31, position converting push bolts 32, 32 are disposed with being aligned up and down. The position converting pull-out bolts 31 and position converting push bolts 32 are disposed, with each being oriented along the opposing direction.

The position converting pull-out bolts 31 are rotatably attached to the block-position reference section 26, and the tip portions thereof protrude through the block-position reference section 26 toward the die block 25 side so as to be screwed into the die block 25. Rotating the position converting pull-out bolts 31 in one direction (e.g., to the left) causes the die block 25 to move away from the moving flat die 4 in the opposing direction. Each of the position converting pull-out bolts 31 is individually rotatable by operation. By individually operating the rotation of the individual position converting pull-out bolts 31, each of the positions close to both ends of the die block 25 (fixed flat die 3) in the rolling direction can be individually converted so as to be away from the moving flat die 4 in the opposing direction.

The position converting push bolts 32 are rotatably attached to the block-position reference section 26, and the tip portions thereof protrude through the block-position reference section 26 toward the die block 25 side so as to abut against the die block 25. Rotating the position converting push bolts 32 in one direction (e.g., to the right) causes the die block 25 to be moved by pressing in the opposing direction approaching the moving flat die 4. Each of the position converting push bolts 32 is individually rotatable by operation. By individually operating the rotation of the individual position converting push bolts 32, each of the positions close to both ends of the die block 25 (fixed flat die 3) in the rolling direction can be individually converted so as to approach the moving flat die 4 in the opposing direction.

Note that, a commonly used mechanism can be applied to the mechanism for adjusting the position of the die block 25 (fixed flat die 3) in the opposing direction by appropriately operating the rotation of the two position converting pull-out bolts 31 and the four position converting push bolts 32. Thus, details thereof will be omitted.

Further, the block-position reference section 26 is provided with opposing-position detecting sensors 33, 33 to detect where the opposing position of the die block 25 (fixed flat die 3) locates (hereinafter, referred to as an opposing-directional position) at respective portions close to both ends of the block-position reference section 26 in the rolling direction (see FIG. 6). The opposing-position detecting sensors 33, 33 detect the respective portions close to both ends of the fixed flat die 3 in the rolling direction. This configuration makes possible the detection of the opposing position of each of the portions close to both ends of the fixed flat die 3.

Moreover, in the embodiment, the fixed flat die 3 is disposed slidably in the rolling direction with respect to the block-position reference section 26 while the fastening bolts 10, 10 are being loosened. Then the block-position reference section 26 includes an adjustment bolt (not shown) for subjecting the fixed flat die 3 to a position conversion in the rolling direction. By rotating the adjustment bolt by operation, the fixed flat die 3 can be slid in the rolling direction. Then the block-position reference section 26 is provided with a rolling-position detecting sensor 34 (see FIG. 6) for detecting the position (hereinafter, referred to as the rolling-directional position) of fixed flat die 3 in the rolling direction.

In this way, the fixed flat die 3 according to the embodiment can be subjected to a position conversion in the opposing direction by rotating both the position converting pull-out bolts 31 and the position converting push bolts 32 by operation, and a positional conversion in the rolling direction by rotating the adjustment bolt by operation, while the fastening bolts 10, 10 are being loosened. Then the fastening bolts 10, 10 are fastened to position and fix the fixed flat die 3.

The rolling apparatus 1 according to the embodiment includes a position detecting device 35 that includes the opposing-position detecting sensors 33, 33 and the rolling-position detecting sensor 34, as shown in FIG. 6. The position detecting device 35 includes a control PC 36 and a touch panel 37. The control PC 36 receives both signals detected by the opposing-position detecting sensors 33, 33 and signals detected by the rolling-position detecting sensor 34. The control PC includes a central controller and a storage device, and controls the display of the touch panel 37.

The position detecting device 35 further includes a top-dead-center detecting sensor 39 for detecting the position of the top dead center of the moving flat die 4. Signals detected by the top-dead-center detecting sensor 39 are fed into the control PC 36. Here, the top-dead-center detecting sensor 39 is intended to detect the top dead center (the starting position of rolling processing), from which the rolling processing is started, of the moving flat die 4, and is disposed in the base table 2.

The storage device of the control PC 36 stores, in advance, product standard information (information on a nominal diameter, a pitch, etc.) regarding threads to be rolling-processed, and various programs or the like with which conditions and the like of the rolling processing are calculated based on the standard information. Specific programs stored in the storage device include a program for calculating a movement amount of reciprocal movement of the moving flat die 4, a program for calculating a correction movement amount that is used to correct the position of the top dead center of the moving flat die 4, and a program for calculating correction position information regarding the opposing-directional position of the fixed flat die 3.

Here, the program for calculating a movement amount of reciprocal movement of the moving flat die 4, calculates the movement amount of reciprocal movement based on outer diameter data of the product standard information described above. Moreover, the program for calculating a correction movement amount of the top dead center, calculates the correction movement amount based on information regarding the nominal diameter, the pitch, etc. according to the product standard information described above, and inputted information inputted by an operator. The inputted information is information inputted through use of the touch panel 37 as described later, is data obtained from actual measurements of a test piece 61 to be described later, and includes information regarding such as a thread direction, the level of the moving flat die 4, and a positional deviation amount P. Through the program, the correction movement amount is calculated using the nominal diameter and pitch according to the product standard information, the positional deviation amount P inputted by an operator as described later, the information inputted by the operator regarding the level of the moving flat die 4, and pi, the ratio of the circumference of a circle to its diameter. According to the thus-calculated correction movement amount, the correction bolt 8 is operated to adjust the moving flat die 4 to be positioned at a proper top dead center.

Moreover, through the program for calculating the correction position information regarding the opposing-directional position of the fixed flat die 3, the correction position information is calculated based on the nominal diameter and pitch according to the product standard information described above, data from the actual measurements of the test piece 61, and the like. Specifically, the correction position information corresponding to each of the positions detected by the opposing-position detecting sensors 33, 33 described above, is calculated using the information, including a bite depth T inputted by an operator as described later, the nominal diameter and pitch according to the product standard information, and the information regarding the opposing-directional position detected by the opposing-position detecting sensors 33, 33 described above. In accordance with the correction position information for each of these detected positions, the position converting pull-out bolts 31 and position converting push bolts 32 are operated to adjust the fixed flat die 3 to be set at a position where the rolling can be performed with an appropriate bite depth.

Under the display control by the control PC, the touch panel 37 displays by switching the correction movement amount of the top dead center of the moving flat die 4 shown in FIG. 7 and the correction position information regarding the opposing-directional position of the fixed flat die 3 shown in FIG. 8. Such a display-switching can be carried out by operation by an operator. Note that, since the operation, processing, etc. of the switching can be applied with conventionally known means, the details thereof will be omitted.

In the case where the correction movement amount of the top dead center of the moving flat die 4 described above is displayed, as shown in FIG. 7, the following parts are displayed on the screen of the touch panel 37. That is, a standard displaying part 41 that selectively displays thread standards (nominal diameter, pitch, thread direction, etc.), a level displaying part 74 that displays the inputted information regarding the level of the moving flat die 4, a positional-deviation-amount displaying part 75 that displays the inputted positional deviation amount P, and a bar-shaped correction graphic part 81. The touch panel 37 is the same as that commonly used, and can be operated by an operator by touching predetermined portions thereof. Specifically, upon touching on the standard displaying part 41 by the operator, one of a plurality of pieces of preset product standard information is selected and displayed. In the correction graphic part 81, at a center portion thereof in the longitudinal direction, there are displayed both a vertical line-shaped target-position displaying part 82 and a vertical line-shaped current-position displaying part 83 corresponding to the correction movement amount. The distance, how far the display position of the current-position displaying part 83 is separated from the target-position displaying part 82, indicates the correction movement amount. As the correction movement amount becomes smaller, the display position of the current-position displaying part 83 approaches the target-position displaying part 82. Then, when the correction movement amount=0 (zero), the current-position displaying part 83 coincides with and is displayed together with the target-position displaying part 82. In addition, the touch panel 37 displays a rotational-direction indication displaying part 78 that indicates the rotary direction of the correction bolt 8 described above, and a target-value achievement displaying part 79 that indicates that the current-position displaying part 83 coincides with the target-position displaying part 82.

On the other hand, when displaying the correction position information regarding the opposing-directional position of the fixed flat die 3, as shown in FIG. 8, the following parts are displayed on the screen of the touch panel 37. That is, the standard displaying part 41 described above; a bite-amount displaying part 44 that displays the inputted bite depth T; first to third current-position displaying parts 43a to 43c that display the current position information regarding the fixed flat die 3 detected by the opposing-position detecting sensors 33, 33 and the rolling-position detecting sensor 34; and first to third correction-position information displaying parts 42a to 42c that display the correction position information regarding the fixed flat die corresponding to the respective detected positions detected by these detecting sensors 33 and 34.

Next, a description will be made regarding a correction method for performing, before rolling processing, position adjustment to both the top dead center of the moving flat die 4 and the opposing-directional position of the fixed flat die 3, in accordance with the product standards (the nominal diameter of the thread). Here, the correction method is performed using a test piece 61 produced by rolling processing a base material 60.

First, the test piece 61 is produced. The production of the test piece 61 is performed under an instruction to produce the test piece 61 via the touch panel 37 (not shown). In the embodiment, the drive controller disposed in the base table 2 described above, performs control steps for producing the test piece in accordance with the operation via the touch panel 37. This drive controller corresponds to the test-movement control means according to the present invention.

More specifically, the product standards (the nominal diameter, pitch, and thread direction) of the thread product to be produced are selectively inputted via the touch panel 37, thereby giving instruction to start steps of producing the test piece 61.

The test piece 61 is produced as follows: The moving flat die 4 is caused to move in the normal direction of the rolling, from the state where, as shown in FIG. 4A, the base material 60 is sandwiched between the fixed-side rolling-surface section 11 of the fixed flat die 3 and the moving-side rolling-surface section 21 of the moving flat die 4 at the top dead center, until the state where, as shown in FIG. 4B, the base material 60 is rotated a half-turn. By this processing, there are formed, in the base material 60, both groove-like fixed-side streaks 62 based on the fixed-side rolling-surface section 11 and moving-side streaks 63 based on the moving-side rolling-surface section 21 (see FIG. 5A and FIG. 5B).

Note that how the moving flat die 4 is caused to move until the base material 60 is rotated a half turn is as follows: Since the nominal diameter, thread pitch, etc. of the thread product to be produced have been inputted in advance, the program of the position detecting device 35 is executed to calculate a movement amount for the moving flat die 4, based on the outer circumferential length of a to-be-processed portion of the test piece 61. Then, the drive controller performs the control under which the moving flat die 4 is automatically moved to go from the top dead center, by the calculated movement amount.

After the base material 60 described above has been rotated a half turn, the moving flat die 4 is automatically recovered to the top dead center (return operation). In this way, the drive controller performs the control to automatically cause the reciprocal movement of the moving flat die 4, which results in the formation of both the fixed-side streaks 62 and moving-side streaks 63 in the base material 60, thereby completing the test piece 61 having these streaks 62 and 63.

In the test piece 61, as shown in FIG. 5A and FIG. 5B, the fixed-side streaks 62 and the moving-side streaks 63 are formed. Here, any one of the grooves formed as the fixed-side streaks 62 is selected. Then, in a front elevation view of the test piece 61, a groove center line, the center line of the selected groove formed along the longitudinal direction thereof, is determined. Then a virtual groove center line W is defined that is obtained by extending this groove center line. A moving-side groove center line V is determined for the corresponding groove formed as the moving-side streaks 63. Then the positional deviation amount P of the moving-side groove center line V is measured with respect to the virtual groove center line W. The positional deviation amount P is measured as a positional deviation amount of the moving-side groove center line V with respect to an appropriate position, in the direction along the axis of the test piece 61, the appropriate position being defined as a position where the moving-side groove center line V coincides with the virtual groove center line W. For example, the moving-side groove center line V is measured to be 0.29 mm lower (i.e., to be farther away from the top of the test piece 61) than the virtual groove center line W of the selected grooved.

The thus-measured positional deviation amount P is inputted via the touch panel 37. As shown in FIG. 7A, while the touch panel 37 displays a screen for use in inputting a positional deviation amount P, an operator inputs the positional deviation amount (specifically, 0.29 mm) into the positional-deviation-amount displaying part 75 described above, and also inputs the position of the moving flat die 4 (specifically whether the level of the moving flat die 4 is lower or higher than the other) into the level displaying part 74.

Upon inputting the positional deviation amount P and the like into the touch panel 37, the position detecting device 35 automatically calculates a correction movement amount to be used for adjusting the top dead center of the moving flat die 4 as described above, by using the nominal diameter, thread pitch, and thread direction according to the product standard information, the inputted information regarding the level of the moving flat die 4, and the inputted positional deviation amount P. Then the touch panel 37 displays the correction graphic part 81 in which the current-position displaying part 83 is displayed at the position that indicates the thus-calculated correction movement amount. In addition, the rotational-direction indication displaying part 78 is also displayed.

While viewing the correction graphic part 81 and the rotational-direction indication displaying part 78, the operator can manipulate the correction bolt 8 such that the current-position displaying part 83 coincides with the target-position displaying part 82, thereby adjusting the top dead center of the moving flat die 4 to the appropriate position where the moving-side groove center line V and the virtual groove center line W are aligned in a straight line. In this way, the operator can manipulate the correction bolt 8 while more visually recognizing the positional deviation and amount thereof of the moving flat die 4.

When the current-position displaying part 83 coincides with the target-position displaying part 82, as shown in FIG. 7B, the target-value achievement displaying part 79 is displayed in place of the rotational-direction indication displaying part 78, which notifies the operator that the positional correction of the moving flat die 4 has been completed. With this configuration, even an unskilled operator can easily correct the position of the die of the rolling apparatus 1.

On the other hand, any groove of either the fixed-side streaks 62 or the moving-side streaks 63 formed in the test piece 61 is selected and the depth of the selected groove is measured. Here, as shown in FIG. 5B, the groove depth is measured as the bite depth T with respective to the outer surface of the test piece 61 before the formation of the fixed-side streaks 62 and the like. For example, the bite depth T is measured to be 0.011 mm.

Here, adjusting the bite depth T makes it possible to adjust rolling pressure and align the pitches. That is, the pitch alignment allows the formation of products having the pitch compliant with the product standards. The adjustment of the rolling pressure allows a reduction in occurrence of slipping during rolling processing. In this way, the pitch alignment and the adjustment of the rolling pressure allows a reduction in occurrence of forming defects in the rolling processing.

The thus-measured bite depth T is inputted via the touch panel 37. As shown in FIG. 8, while the touch panel 37 displays a screen for use in inputting the bite depth T, the operator inputs the bite depth T (specifically, 0.011 mm) into the bite-amount displaying part 44 described above.

Upon inputting the aforementioned bite depth T into the touch panel 37, as described earlier, the position detecting device 35 automatically calculates the correction position information corresponding to each of the detecting sensors 33, 33 for use in adjusting the opposing-directional position of the fixed flat die 3, by using the nominal diameter and pitch according to the product standard information, the information regarding the current opposing-directional position of the fixed flat die 3 detected by the opposing-position detecting sensors 33, 33, and the thus-inputted bite depth T. Then these pieces of the correction position information are displayed on the respective correction-position information displaying parts 42a to 42c on the touch panel 37, and also the pieces of the current position information of the fixed flat die 3 are displayed on the respective current-position displaying parts 43a to 43c on the touch panel 37.

The operator loosens the fastening bolts 10, 10, which are fixing the fixed flat die 3, thereby making slidable the fixed flat die 3 in both the opposing direction and the rolling direction. Then the operator manipulates the position converting pull-out bolts 31, the position converting push bolts 32, and the adjustment bolt while comparing the correction-position information displaying parts 42a to 42c to the current-position displaying parts 43a to 43c, respectively. With this operation, each of the pieces of the information indicated in the current-position displaying parts 43a to 43c is caused to coincide with the correction position information indicated in the respective correction-position information displaying parts 42a to 42c. This makes it possible to adjust the opposing-directional position of the fixed flat die 3 to be at the appropriate position, which facilitates the rolling processing at a desired bite depth (a desired rolling pressure and a pitch compliant with the product standards). In this way, while visually recognizing the opposing-directional position and correction position information of the fixed flat die 3, the operator can manipulate the position converting pull-out bolts 31, the position converting push bolts 32, and the adjustment bolt.

Note that the reason why the test piece 61 is rotated a half turn when adjusting both the position of the top dead center and the opposing-directional position of the fixed flat die 3, is as follows: First, the fixed-side streaks 62 and the moving-side streaks 63 must not overlap one another. Second, it also facilitates the measurement of the positional deviation amount, which is calculated between the virtual groove center line W obtained by extending the groove center line of the fixed-side streak 62 and the moving-side groove center line V of the moving-side streak 63. Therefore, the base material 60 may be rotated less than or equal to a half turn as long as it is possible to properly measure the positional deviation amount P between the virtual groove center line W and the moving-side groove center line V. Note that, in the case where the base material 60 is rotated more than a half turn, the fixed-side streaks 62 and the moving-side streaks 63 are formed with both overlapping one another, which would make it difficult to correctly recognize both center lines W and V. Moreover, the overlap between the fixed-side streaks 62 and the moving-side streaks 63 would also make it difficult to properly measure the bite depth T.

In this way, in the rolling apparatus 1 according to the embodiment, there are calculated both the correction movement amount for adjusting the position of the top dead center of the moving flat die 4 and the correction position information for adjusting the position of the fixed flat die 3, by using the positional deviation amount P and bite depth T, which both are obtained by measuring from the fixed-side streaks 62 and moving-side streaks 63 formed in the test piece 61. Then the thus-calculated information is displayed on the touch panel 37. While viewing the touch panel 37, the operator can adjust the position of the top dead center of the moving flat die 4 by manipulating the correction bolt 8, and also adjust the opposing-directional position of the fixed flat die 3 by manipulating both the position converting pull-out bolts 31 and the position converting push bolts 32. In this way, since these positional adjustments can be performed through such visual recognition, it makes easy and stable these positional adjustments. With this configuration, without relying on experience and intuition, the operator easily and correctly adjusts the positions of the moving flat die 4 and the fixed flat die 3, at the respective processing-start positions suitable for the male threads to be rolled. Moreover, since the present embodiment involves a function of assisting an operator in working, i.e., in adjusting the positions of the moving flat die 4 and the fixed flat die 3, it may be used for skill training through actual work, i.e., work of these positional adjustments. This facilitates efficient progress of improvement in operator's skill, and is also usable for inheritance of skill and the like

In addition, according to the configuration of the embodiment, variations in quality due to differences in proficiency among operators are reduced, which results in a decrease in the burden on the quality control of the threads and an advantage of improved lives of dies. Further, the time required for advance preparation is shortened, resulting in a reduced workload of operators and also an advantage of an improved ratio of utilization of the rolling apparatus. A reduced cost is also expected in preparing blank workpieces before the main processing.

In the configuration of the embodiment described above, the correction bolt 8 corresponds to the top-dead-center position adjusting means according to the present invention. The control PC 36 and the touch panel 37 correspond to the positional-deviation-amount inputting means and bite inputting means according to the present invention. The touch panel 37 corresponds to the display section according to the present invention. The position detecting device 35 corresponds to the correction-movement-amount calculation controlling means and adjustment-value outputting means according to the present invention. The position converting pull-out bolts 31 and the position converting push bolts 32 correspond to the opposing-position adjusting means according to the present invention. The opposing-position detecting sensors 33, 33 correspond to the opposing-position detecting means according to the present invention. The first and second current position information corresponds to the detected opposing-position information according to the present invention. The correction graphic part 81 corresponds to the movement-amount corresponding graphic part according to the present invention.

In the embodiment, the dimensions and shape of each part can be freely chosen as appropriate.

For example, it may be configured to automatically control to rotate the correction bolt in accordance with the correction movement amount. Further, the means configurated to adjust the position is not limited to the correction bolt, and other configurations such as a turnbuckle may of course be used.

In addition, the positional deviation amount of the moving-side groove center line with respect to the virtual groove center line may be automatically measured from the information captured by a camera installed in the rolling apparatus. Similarly, it is also possible to automatically measure the bite depth of the test piece from the information captured by the camera.

Although, in the rolling apparatus according to the embodiment, the fixed flat die is configured to be movable in the opposing direction and thus the opposing-directional position thereof is adjustable, the configuration of the rolling apparatus is not limited to this. Instead, the moving flat die may be configured to be movable in the opposing direction, and thus the opposing-directional position of the moving flat die is adjusted so as to adjust the bite depth. Alternatively, both the fixed flat die and the moving flat die may be configured to be movable in the opposing direction, and their respective opposing-directional positions may be adjustable.

Although, the rolling apparatus of the embodiment is configured to include the top-dead-center detecting sensor that detects the position of the top dead center of the moving flat die, the configuration of the rolling apparatus is not limited to this. Various means capable of measuring the position of the moving flat die can be applied. For example, a means may be disposed for measuring the distance (movement amount) of moving of the moving flat die, thereby determining the position of the moving flat die based on the movement amount. In this configuration, the correction movement amount described above and the movement amount of moving of the moving flat die can be used to adjust the moving flat die at the desired top dead center.

The rolling apparatus according to the embodiment is configured such that the position converting pull-out bolts and the position converting push bolts are disposed at respective portions close to both ends of the fixed flat die, but the configuration of the rolling apparatus is not limited to this. The number and arrangement locations of both the position converting pull-out bolts and the position converting push bolts may be changed as appropriate. For example, one position converting pull-out bolt and one position converting push bolt may be disposed approximately at the center of the fixed flat die in the rolling direction, and thus the opposing-directional position of the fixed flat die is adjusted by rotating these bolts by manipulation. Alternatively, three or four position converting pull-out bolts and three or four position converting push bolts may also be disposed.

The rolling apparatus according to the embodiment is configured such that the opposing-directional position of the fixed flat die can be converted by individually rotating the position converting pull-out bolts and the position converting push bolts, but the configuration of the rolling apparatus is not limited to this. The position of fixed flat die may also be converted in the opposing direction by using one position converting bolt. The number and arrangement locations of such position converting bolts may be determined as appropriate.

Although the embodiment described above is an example of the rolling apparatus for rolling male threads, it is also applicable to an apparatus that performs rolling processing of products other than male threads. For example, it is also applicable to a rolling apparatus that performs knurling processing, a rolling apparatus that performs form rolling processing (grooving processing, etc.), and any other apparatus, resulting in improved work efficiency and stabilized quality in the same manner as the example described above.

REFERENCE SIGNS LIST

• • 1 rolling apparatus
  • 2 base table
  • 3 fixed flat die
  • 4 moving flat die
  • 8 correction bolt
  • 11 fixed-side rolling-surface section
  • 21 moving-side rolling-surface section
  • 31 position converting pull-out bolt
  • 32 position converting push bolt
  • 33 opposing-position detecting sensor
  • 35 position detecting device
  • 36 control PC, 37 touch panel
  • 60 base material
  • 61 test piece
  • 62 fixed-side streak
  • 63 moving-side streak
  • V moving-side groove center line
  • W virtual groove center line
  • P positional deviation amount
  • T bite depth