CA1129187A - Method of forming a flex-plate and gear member from a thin metal disc - Google Patents
Method of forming a flex-plate and gear member from a thin metal discInfo
- Publication number
- CA1129187A CA1129187A CA346,151A CA346151A CA1129187A CA 1129187 A CA1129187 A CA 1129187A CA 346151 A CA346151 A CA 346151A CA 1129187 A CA1129187 A CA 1129187A
- Authority
- CA
- Canada
- Prior art keywords
- disc
- outer periphery
- flex
- plate
- forming
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
- 239000002184 metal Substances 0.000 title claims abstract description 12
- 238000000034 method Methods 0.000 title claims description 10
- 238000010438 heat treatment Methods 0.000 claims description 3
- 238000005096 rolling process Methods 0.000 description 5
- 239000000463 material Substances 0.000 description 3
- 230000006698 induction Effects 0.000 description 2
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 230000000750 progressive effect Effects 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21H—MAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS
- B21H1/00—Making articles shaped as bodies of revolution
- B21H1/02—Making articles shaped as bodies of revolution discs; disc wheels
- B21H1/04—Making articles shaped as bodies of revolution discs; disc wheels with rim, e.g. railways wheels or pulleys
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21H—MAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS
- B21H5/00—Making gear wheels, racks, spline shafts or worms
- B21H5/02—Making gear wheels, racks, spline shafts or worms with cylindrical outline, e.g. by means of die rolls
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21H—MAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS
- B21H5/00—Making gear wheels, racks, spline shafts or worms
- B21H5/04—Making gear wheels, racks, spline shafts or worms bevel gears
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/14—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass gear parts, e.g. gear wheels
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Forging (AREA)
- Gears, Cams (AREA)
- Heat Treatment Of Articles (AREA)
Abstract
Abstract of the Disclosure An integral flex-plate and gear are formed from a thin metal disc by upsetting the outer periphery to form a flange on which gear teeth are then formed.
Portions of the central area of the disc are removed so that a flexible hub portion is produced.
Portions of the central area of the disc are removed so that a flexible hub portion is produced.
Description
1~2~187 A METHOD OF FORMING A
FLEX-PLATE AND GEAR MEMBER
This invention relates to gear making and more particularly to methods of manufacturing-integral flex-plate and gear members from a flat thin metal disc.
A flex-plate is secured between an engine crankshaft and a torque converter input of an auto-matic transmission to permit slight misalignments which occur between these devices. A ring gear is secuxed to the outer periphery of the flex-plate, which ring gear provides a starter gear for the engine.
It has been the common practice to make combination flex-plate and ring gears by stamping the flex-plate from a sheet metal disc to which is then welded a ring gear which is formed from rectangular bar stock which has been rolled and welded in a ring after which the gear teeth are formed thereon. Thus, prior art flex-plate and ring gear structures have been manufactured from }
1~9~87 two separate pieces which require excessive handling during the manufacturing process.
The present invention utilizes a method of forming an integral ring gear and flex-plate from a thin metal disc by upset rolling the outer periphery of the disc to form a flange, extruding or otherwise forming teeth in the flange, and piercing the central portion of the disc to form a flexible hub portion.
It is an object of this invention to-provide an improved method of forming a flex-plate and gear member from a thin metal disc.
It is another object of this invention to provide an improved method of forming an integral gear member and flex-plate from a flat metal disc wherein the disc is simultaneously supported axially on both sides for a small arcuate distance, heated for a small arcuate distance, and deformed radially inwardly adjacent the support position to form a flange on the outer periphery of the disc, after which gear teeth are formed in the flanged surface.
These and other objects and advantages of the present invention will be more apparent from the following description and drawings in which:
Figure 1 is a perspective view of the various shapes the sheet metal disc acquires during this process;
~2gl~7 Figure 2 is a diagrammatic representation of the flange forming mechanism; and Figures 2a through 2d are cross-sectional views which show the flange forming which occur~
using the mechanism of Figure 2.
- Referring to the drawings, there is seen in Figure lA a flat metal disc 10 having a flat central portion 12 and an outer periphery 14. In Figure 1~, the disc 10 has had the outer periphery thereof deformed into a flanged portion 14a. In Figure lC, a plurality of gear teeth 16 have been formed in the flange portion 14a of metal disc 10.
These gear teeth 16 may be formed in a number of ways such as by extruding. In Figure lD, the flat central portion 12 has been indented to form a plurality of lug portions 18 and a central crankshaft mounting portion 20. The central portion 12 has also been pierced at a plurality of locations 22 to remove material therefrom thus forming a flexible hub portion between the flange 14a and the crankshaft hub 20. The lug portions 18 each have an aperture 24 formed therein which permit the disc 10 to be secured to a torque converter in a well ~nown manner. The removal of material and the indenting as shown in Figure lD can be accomplished in a single piercing operation or in a plurality of operations as desired.
~Z9~87 In .igure 2, the disc 10 is shown as being supported between two rollers 26 and 28 which contact the disc 10 for a small arcuate distance radially inwardly from the outer surface 14. The disc 10 is adapted to be rotated such that the periphery 14 will be continuously passed through an induction heating element 30 which is disposed substantially diametrically opposite the position at which the support rollers 26 and 23 abut the disc 10. A
carousel 32 has rotatably supported therein a plurality of rolling dies designated I, II, III
and IV. The carousel 32 is movable toward the center of disc 10 such that the rolling dies I
through IV can be brought into contact with the outer periphery 14 of disc 10.
As seen in Figure 2a, the die I, as it progresses radially inward relative to disc 10, causes the periphery 14 to bulge. The left side of Figure 2a shows the position of die I prior to radial movement inward while the righthand side of Figure 2a shows the position of die I at the end of its radial inward movement where it is in contact with the rollers 26 and 2~. When die I
has completed its radially inward travel, the carousel 32 is progressed so that die II comes into abutment with the outer periphery 14. The carousel 32 is then progressed radially inward l~Z91~7 toward disc 10 so as to further deform the outer periphery 1~ of the disc 10. In Figure 2b, the lefthand side of Figure 2b shows the position of die II prior to movement of the carousel 32 and the righthand portion of Figure 2b shows the full movement of carousel 32 and the corresponding deformation of the outer periphery 14 of disc 10.
Figures 2c and 2d show the further progressive deformation of the outer periphery 14 of disc 10.
As shown in the righthand side of Figure 2d, a completed flange 14a is formed on the outer periphery of disc 10. It is this flanged portion that has the gear teeth 16 formed therein. The induction heater 30 maintains the outer surface of disc 10 at a temperature in the range of 1300 to 1400 F., thus reducing the forces necessary for rolling the flange portion of disc 10.
When the disc 10 has reached its final shape as shown in Figure lD, it may be heat treated and balanced as desired. It should be appreciated from the above description that using the subject process reduces the material handling problems previously associated with two-piece flex-plating gear assemblies. The present method requires that only a thin metal disc be handled from start to finish and that there is no requirement to fixture a flex-plate and ring gear so that they can be ~Zgl87 joined by welding. The thickness of the flange 14a can be controlled by the design of the rolling dies I through IV so that the sizes of the gear teeth to be formed therein will be readily accommodated.
FLEX-PLATE AND GEAR MEMBER
This invention relates to gear making and more particularly to methods of manufacturing-integral flex-plate and gear members from a flat thin metal disc.
A flex-plate is secured between an engine crankshaft and a torque converter input of an auto-matic transmission to permit slight misalignments which occur between these devices. A ring gear is secuxed to the outer periphery of the flex-plate, which ring gear provides a starter gear for the engine.
It has been the common practice to make combination flex-plate and ring gears by stamping the flex-plate from a sheet metal disc to which is then welded a ring gear which is formed from rectangular bar stock which has been rolled and welded in a ring after which the gear teeth are formed thereon. Thus, prior art flex-plate and ring gear structures have been manufactured from }
1~9~87 two separate pieces which require excessive handling during the manufacturing process.
The present invention utilizes a method of forming an integral ring gear and flex-plate from a thin metal disc by upset rolling the outer periphery of the disc to form a flange, extruding or otherwise forming teeth in the flange, and piercing the central portion of the disc to form a flexible hub portion.
It is an object of this invention to-provide an improved method of forming a flex-plate and gear member from a thin metal disc.
It is another object of this invention to provide an improved method of forming an integral gear member and flex-plate from a flat metal disc wherein the disc is simultaneously supported axially on both sides for a small arcuate distance, heated for a small arcuate distance, and deformed radially inwardly adjacent the support position to form a flange on the outer periphery of the disc, after which gear teeth are formed in the flanged surface.
These and other objects and advantages of the present invention will be more apparent from the following description and drawings in which:
Figure 1 is a perspective view of the various shapes the sheet metal disc acquires during this process;
~2gl~7 Figure 2 is a diagrammatic representation of the flange forming mechanism; and Figures 2a through 2d are cross-sectional views which show the flange forming which occur~
using the mechanism of Figure 2.
- Referring to the drawings, there is seen in Figure lA a flat metal disc 10 having a flat central portion 12 and an outer periphery 14. In Figure 1~, the disc 10 has had the outer periphery thereof deformed into a flanged portion 14a. In Figure lC, a plurality of gear teeth 16 have been formed in the flange portion 14a of metal disc 10.
These gear teeth 16 may be formed in a number of ways such as by extruding. In Figure lD, the flat central portion 12 has been indented to form a plurality of lug portions 18 and a central crankshaft mounting portion 20. The central portion 12 has also been pierced at a plurality of locations 22 to remove material therefrom thus forming a flexible hub portion between the flange 14a and the crankshaft hub 20. The lug portions 18 each have an aperture 24 formed therein which permit the disc 10 to be secured to a torque converter in a well ~nown manner. The removal of material and the indenting as shown in Figure lD can be accomplished in a single piercing operation or in a plurality of operations as desired.
~Z9~87 In .igure 2, the disc 10 is shown as being supported between two rollers 26 and 28 which contact the disc 10 for a small arcuate distance radially inwardly from the outer surface 14. The disc 10 is adapted to be rotated such that the periphery 14 will be continuously passed through an induction heating element 30 which is disposed substantially diametrically opposite the position at which the support rollers 26 and 23 abut the disc 10. A
carousel 32 has rotatably supported therein a plurality of rolling dies designated I, II, III
and IV. The carousel 32 is movable toward the center of disc 10 such that the rolling dies I
through IV can be brought into contact with the outer periphery 14 of disc 10.
As seen in Figure 2a, the die I, as it progresses radially inward relative to disc 10, causes the periphery 14 to bulge. The left side of Figure 2a shows the position of die I prior to radial movement inward while the righthand side of Figure 2a shows the position of die I at the end of its radial inward movement where it is in contact with the rollers 26 and 2~. When die I
has completed its radially inward travel, the carousel 32 is progressed so that die II comes into abutment with the outer periphery 14. The carousel 32 is then progressed radially inward l~Z91~7 toward disc 10 so as to further deform the outer periphery 1~ of the disc 10. In Figure 2b, the lefthand side of Figure 2b shows the position of die II prior to movement of the carousel 32 and the righthand portion of Figure 2b shows the full movement of carousel 32 and the corresponding deformation of the outer periphery 14 of disc 10.
Figures 2c and 2d show the further progressive deformation of the outer periphery 14 of disc 10.
As shown in the righthand side of Figure 2d, a completed flange 14a is formed on the outer periphery of disc 10. It is this flanged portion that has the gear teeth 16 formed therein. The induction heater 30 maintains the outer surface of disc 10 at a temperature in the range of 1300 to 1400 F., thus reducing the forces necessary for rolling the flange portion of disc 10.
When the disc 10 has reached its final shape as shown in Figure lD, it may be heat treated and balanced as desired. It should be appreciated from the above description that using the subject process reduces the material handling problems previously associated with two-piece flex-plating gear assemblies. The present method requires that only a thin metal disc be handled from start to finish and that there is no requirement to fixture a flex-plate and ring gear so that they can be ~Zgl87 joined by welding. The thickness of the flange 14a can be controlled by the design of the rolling dies I through IV so that the sizes of the gear teeth to be formed therein will be readily accommodated.
Claims
1. A method of forming a flex-plate and gear blank member from a flat thin metal disc comprising:
rotating the disc on the central axis thereof;
supporting the disc for a small arcuate distance on both sides adjacent the outer periphery with a pair of rotating support rollers;
maintaining the disc thickness unchanged immediately axially adjacent and radially inward of the rotary support position of said support rollers;
heating the outer periphery during rotation;
and progressively deforming the outer periphery radially inward against the support rollers during the rotation and heating of the disc to form a flanged outer periphery which extends axially outward from both sides of the disc immediately radially outward of said support rollers.
rotating the disc on the central axis thereof;
supporting the disc for a small arcuate distance on both sides adjacent the outer periphery with a pair of rotating support rollers;
maintaining the disc thickness unchanged immediately axially adjacent and radially inward of the rotary support position of said support rollers;
heating the outer periphery during rotation;
and progressively deforming the outer periphery radially inward against the support rollers during the rotation and heating of the disc to form a flanged outer periphery which extends axially outward from both sides of the disc immediately radially outward of said support rollers.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US2808879A | 1979-04-09 | 1979-04-09 | |
| US028,088 | 1979-04-09 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1129187A true CA1129187A (en) | 1982-08-10 |
Family
ID=21841505
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA346,151A Expired CA1129187A (en) | 1979-04-09 | 1980-02-21 | Method of forming a flex-plate and gear member from a thin metal disc |
Country Status (4)
| Country | Link |
|---|---|
| JP (1) | JPS55139553A (en) |
| CA (1) | CA1129187A (en) |
| DE (1) | DE3006201A1 (en) |
| GB (1) | GB2045665B (en) |
Families Citing this family (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE69013514T2 (en) * | 1990-07-20 | 1995-02-23 | Kanemitsu Akashi Kk | METHOD FOR PRODUCING COMPONENTS OF A LIQUID CHAMBER. |
| JP2826913B2 (en) * | 1990-12-28 | 1998-11-18 | 株式会社久保田鉄工所 | Drive plate manufacturing method |
| JP3364811B2 (en) * | 1994-04-22 | 2003-01-08 | 株式会社久保田鉄工所 | Gear manufacturing equipment |
| DE19549714B4 (en) * | 1994-04-22 | 2006-06-22 | Kubota Iron Works Co., Ltd. | Procedure and equipment for mfg. gearwheels - with stages including clamping disc=form blank, heating up outer circumferential region to 400=500 deg C, and then forging it to form thickened section for pressing for plastic deformation |
| DE19581538B4 (en) * | 1995-01-27 | 2005-10-20 | Kanemitsu Corp | A method of thickening an annular peripheral wall of a sheet metal member |
| JP3371276B2 (en) * | 1995-06-30 | 2003-01-27 | 株式会社久保田鉄工所 | Forming method of disk-shaped material |
| DE19617826C2 (en) * | 1996-05-03 | 2001-02-01 | Leifeld Gmbh & Co | Method and press device for producing a machine element with external teeth |
| WO1998001246A1 (en) * | 1996-07-10 | 1998-01-15 | Kabushiki Kaisha Kanemitsu | Shaped article of sheet metal having peripheral wall and method of increasing peripheral wall thickness |
| DE102012214870A1 (en) * | 2012-08-22 | 2014-02-27 | Schaeffler Technologies AG & Co. KG | Drive wheel, has opening for retaining shaft, teeth formed at peripheral surface of wheel using rolling method, and carrier body arranged at peripheral surface of wheel, where wheel is designed as thin-walled circular blank |
| DE102015116653A1 (en) * | 2015-10-01 | 2017-04-06 | WF Maschinenbau und Blechformtechnik GmbH & Co. KG | Method and device for producing a rotationally symmetrical transmission part |
| CN110153646A (en) * | 2019-04-30 | 2019-08-23 | 海盐猛凌汽车配件有限公司 | A kind of engagement hub of a spool bracing strut processing technology |
-
1980
- 1980-02-15 DE DE19803006201 patent/DE3006201A1/en not_active Withdrawn
- 1980-02-21 CA CA346,151A patent/CA1129187A/en not_active Expired
- 1980-04-09 GB GB8011655A patent/GB2045665B/en not_active Expired
- 1980-04-09 JP JP4579980A patent/JPS55139553A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| GB2045665A (en) | 1980-11-05 |
| JPS55139553A (en) | 1980-10-31 |
| DE3006201A1 (en) | 1980-10-30 |
| GB2045665B (en) | 1982-11-24 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |