EP3246104A1 - Method and device for manufacturing a formed element - Google Patents

Abstract

The invention relates to a method and an apparatus for producing a forming part (9) from a blank (1), wherein the blank (1) is set in rotation and at least one compression roll (50) is radially delivered to an outer edge of the blank (1). which has a circumferential shaping groove (56). The outer edge of the blank (1) is compressed to a thickened area, which is formed according to the forming groove (56) of the compression roller (50) to a thickened edge contour. In radial compression at least two axial forming rollers (41, 42) are delivered to an outer region of the Ronde (1), which cooperate in forming the edge contour. According to the invention, it is provided that the two axial forming rollers (41, 42) are delivered to each other at least in an initial phase of radial compression at the thickened region with an axial forming distance which is smaller than an axial width of the forming groove (56) of the compression roll ( 50), wherein the thickened portion is axially backpressed.

Description

The invention relates to a method for producing a forming part from a blank, in which the blank is set in rotation and is radially fed to an outer edge of the blank at least one compression roll, which has a circumferential shaping groove, the outer edge of the blank is compressed to a thickened region, which is formed in accordance with the forming groove of the compression roller to a thickened edge contour, and the radial upsetting to an outer region of the Ronde laterally at least two axial forming rollers are switched on or assist, which cooperate in forming the edge contour, according to the preamble of claim 1.

The invention further relates to a compression roller having a roller base body with an upsetting region, which has a circumferential shaping groove for compressing and forming an edge region of the disc, according to the preamble of claim 9.

Furthermore, the invention relates to an apparatus for producing a Umformteils from a Ronde, with a drive device for rotating driving a Ronde and with at least one compression roller which is radially deliverable to the Ronde for compressing the outer edge of the Ronde, according to the preamble of claim 12th

It is known to compress a blank, that is to say a rotationally symmetrical sheet metal workpiece, by radially feeding an upsetting roll with a peripheral upsetting or shaping groove for forming a material accumulation. In the accumulation of material then, for example, a toothing for forming a gear or a starter ring can be formed without cutting or cut span removing. Due to the radial delivery of the compression roller considerable radial forces are exerted on the Ronde. To avoid kinking the Rondenrandes when upsetting, it is from the DE 102 11 135 B4 known to support the Ronde by lateral support rollers immediately below the compression area.

From the DE 196 02 298 C2 It is also known to use the lateral support rollers as a kind of lateral abutment, which contributes to the radial formation of the edge bead of the blank. The forming rollers can mitausformen a radially inner bottom edge of the edge contour.

When radial upsetting a Rondenrandes by means of a compression roller with circumferential mold groove occur significant loads on the compression roller. As soon as the groove bottom of the forming groove is in contact with the outer rim of the blank, material of the blank is initially displaced axially on both sides by the radial feed of the compression roll. The displaced material is then directed radially inwardly along the flanks of the compression roll with increasing radial feed and further thickened, wherein the diameter of the tube is gradually reduced. In this case, occurs along the edges of the forming groove considerable friction due to the different movement between Ronde and compression roll in the circumferential direction. It can result in a correspondingly strong friction heating, by which the microstructure of the workpiece can be affected.

To reduce the burden is from the WO 96/22847 A1 or the US 5,878,493 A known to perform the upsetting stepwise with several different compression rollers, which have different flank angles in the form of grooves. The use of a variety of different compression rollers is costly and time consuming.

The invention has for its object to provide a method, a compression roller and a device with which a forming part can be processed from a Ronde particularly efficient with thickening of Rondenrandes.

The object is achieved by a method having the feature of claim 1, a compression roller having the feature of claim 9 and an apparatus having the features of claim 12. Preferred embodiments of the invention are specified in the respective dependent claims.

The inventive method is characterized in that the two axial forming rollers are delivered to each other at least in an initial phase of the radial compression to the thickened region with an axial Frontgebungsabstand, which is smaller than an axial width of the forming groove of the compression roll, wherein the thickened region is axially back-plunged ,

A basic idea of the invention is, at least in an initial phase of the radial compression of a blank, to relieve the at least one compression roller in that these side flanks of the thickened region are acted upon directly by two axial forming rollers. The axial distance of the two opposing forming rollers is adjusted so that it is at least partially smaller than an axial width of the forming groove of the compression roller. By the two axial forming rollers so the thickened area is back-ejected after exiting the forming groove of the compression roller axially to a thickness which is smaller than a width of the forming groove. As a result of this back-upsetting of the thickened region in the axial direction, upon re-entry of the back-upsided region into the compression roll, the contact surface and thus the friction between the flanks of the shaping groove and the flanks of the thickened region are reduced. As a result, the load on the compression roller, the friction wear and the friction heating in the forming zone are correspondingly reduced. This makes it possible to achieve a generally gentler forming both for the structure of the workpiece and for the compression roller itself.

A particularly good friction reduction can be achieved according to a development of the invention in that the at least two axial forming rollers are switched on or delivered immediately behind and / or in front of the compression roller. The paired forming rollers can be arranged only a few cm behind or in front of the compression roller.

A further advantageous embodiment of the invention is that the two axial forming rollers are adjusted axially to each other during the upsetting. The axial forming rollers each have an axis of rotation which is radially directed to the axis of rotation of the blank. The axial distance of the two axial forming rollers to each other is a distance which is preferably parallel to the axis of rotation of the Ronde. The axes of rotation of the axial forming rollers may also be angled relative to the radial direction, so that a back-upsetting also on inclined flanks the thickened edge region of the Ronde is made possible. By an axial adjustment of the forming rollers to each other, the contact surface between Ronde and forming rollers can be adjusted, which changes according to the friction. In particular, towards the end of the radial compression, an axial distance of the axial forming rollers can be increased to each other, so that a final shaping takes place substantially through the forming groove of the compression roller. The forming rollers may have radially projecting shoulders, which serve as a stop or stop edge to form approximately a radial inner or underside of the edge contour.

Furthermore, it is advantageous according to an embodiment of the method according to the invention that the two axial forming rollers are radially adjusted during the upsetting. In this way, in particular, an adaptation to a gradual reduction of the diameter of the tube during upsetting can take place.

For a precise shaping of the thickened edge contour, it is advantageous according to an embodiment variant of the invention that in an end phase of the radial compression, the axial forming rollers are spaced from the thickened region and the thickened region is finally shaped to the edge contour by the at least one compression roller. In this case, the forming groove is formed in the compression roller according to the edge contour of the blank to be formed.

A particularly efficient variant of the method according to an embodiment of the invention is that in the same clamping of the blank, an outer edge with the molded-on thickened edge contour is transferred to a spinning tool and a circumferential wall region is formed. The blank is clamped between the spinning tool and a counterholder. In a first step, an edge thickening is carried out, in which case the thickened region of the circular blank is subsequently transferred to the spinning lining in the same clamping operation. In this way, a cylindrical or cup-shaped workpiece with an inner contour can preferably be produced without cutting in accordance with the outer contour of the spinning tool.

It is particularly advantageous that the transfer be carried out by means of at least one compression roller. The compression roller has a multiple function. This multifunctional upset roller reduces the number of necessary pressure rollers and tools.

For efficient shaping according to a variant of the invention, it is advantageous that when folding the thickened edge contour in an external profile, in particular a keyway or a toothing is formed, which is formed on the spinning chuck. It forms on the peripheral wall of a corresponding inner profile. In principle, other profiles and contours can be molded.

The compression roll according to the invention is characterized in that in addition a radially projecting pressure region is provided, which is designed for pressing and / or for pressure-rolling.

The compression roller can thus fulfill a dual function. It is used for radial compression with radial force application and for transferring the radial edge region of the Ronde axially on the spinning chuck, wherein substantially axial forces are applied. The compression roller is thus formed with a pivot bearing which receives both radial and axial forces.

A preferred embodiment of the compression roller according to the invention is that the compression area are arranged in an axial center portion and the pressing portion in a lateral edge portion of the roller body. The pressing region is radially projecting and has a pressing radius.

According to a variant embodiment, it is particularly advantageous for the pressing region to have, in cross-section, a radially projecting nose with a pressing radius and an inlet and / or outlet slope. The inlet bevel can in particular be designed so that a folding of the radially directed Ronde section is effected by an axial movement of the compression roller.

The inventive device for producing a forming part from a blank is characterized in that the above-described compression roller is provided.

It is according to an embodiment of the invention particularly preferred that for clamping the Ronde a spinning chuck is provided, on which an outer profiling is formed, on which an edge portion of the blank for forming a Umformteils with inner profiling can be folded. The spinning lining is part of it a clamping device, wherein the Ronde is axially clamped between the spinning chuck and a counter-holder. Due to the preceding thickening, sufficient material is available to fill the external profile reliably.

Fig. 1

eine Teilquerschnittsansicht durch eine erfindungsgemäße Vorrichtung beim Beginn eines radialen Stauchens einer Ronde;

Fig. 2

eine Darstellung gemäß Fig. 1 zum Ende des radialen Stauchens der Ronde;

Fig. 3

eine Teilquerschnittsansicht der Ronde vor dem Stauchen;

Fig. 4

eine Teilquerschnittsansicht der Ronde nach dem Stauchen;

Fig. 5

eine schematische Seitenansicht der erfindungsgemäßen Vorrichtung entsprechend Fig. 2;

Fig. 6

eine Teilquerschnittsansicht der erfindungsgemäßen Vorrichtung beim Umlegen eines Rondenrandes auf ein profiliertes Drückfutter; und

Fig. 7

eine Teilquerschnittsansicht entsprechend Fig. 6 beim Endformen eines Umformteiles.

The invention will be further described by means of preferred embodiments, which are shown schematically in the accompanying drawings. In the drawings show:

Fig. 1

a partial cross-sectional view through a device according to the invention at the beginning of a radial upsetting of a blank;

Fig. 2

a representation according to Fig. 1 to the end of the radial upsetting of the blank;

Fig. 3

a partial cross-sectional view of the blank before upsetting;

Fig. 4

a partial cross-sectional view of the blank after upsetting;

Fig. 5

a schematic side view of the device according to the invention Fig. 2 ;

Fig. 6

a partial cross-sectional view of the device according to the invention when transferring a Rondenrandes on a profiled spinning lining; and

Fig. 7

a partial cross-sectional view corresponding Fig. 6 during final forming of a formed part.

According to Fig. 1 In a device 10 according to the invention for producing a forming part, a rotationally symmetrical blank 1 made of a sheet metal material is clamped axially between a spinning chuck 12 and a counterholder 20. About a rotary drive, not shown, the clamped Ronde 1 is set in rotation.

Radially from the outside, a compression roller 50 is delivered with a roller body 52 to an outer edge of the blank 1. An upsetting region 54 with a circumferential shaping groove 56 is formed on the roller main body 52 in a middle section. The outer edge of the blank 1 is received in the forming groove 56, which defines an outer contour of the blanking area to be compressed.

The roller main body 52 is attached to a compression roller shaft 74 which is rotatably supported by a radial bearing 76 and a thrust bearing assembly 78 in a holder 80. About the storage by means of radial bearings 76 and thrust bearing 78 both forming forces in the radial direction and in the axial direction can be added.

Radially opposite to the compression roller 50, a first axial forming roller 41 and a second axial forming roller 42 are provided, which are employed axially opposite to the Ronde 1 to be formed. In the forming area, the first axial forming roller 41 and the second axial forming roller 42 have an axial forming pitch which is smaller than an axial width of the forming groove 56 of the compression roller 50. The two forming rollers 41, 42 are respectively attached to a roller shaft 43 which is rotatable are stored in a first roller holder 45 and a second roller holder 46. The first roller holder 45 and the second roller holder 46 are adjustably mounted on a guide support 48. The adjustment can be made via an adjusting device, not shown, in particular adjusting cylinder or a spindle drive.

By radially feeding the compression roller 50 to the rotating Ronde 1, the outer edge of the Ronde 1 is compressed. In this case, the compressed material initially applies to a groove bottom 59 and then to flanks 58 of the molding groove 56. Unlike the groove bottom 59, the flanks 58 of the forming roller 50 and the adjacent material of the blank 1 to a different direction of movement. To reduce the friction, the two axial forming rollers 41, 42 are axially delivered to the thickening Rondenrand, with a certain axial Rückstauchen, for example, about 10% of the wall thickness, the thickened portion of the round blank 1 takes place. As a result, a friction contact is at least reduced upon re-entry of the thickened area in the compression roller 50. As a result, the friction wear, a gefügeschädigende friction heating and a load of the compression roller 50 reduce significantly.

At the end of the shaping of the thickened edge contour 3 of the round blank 1, the axial forming rollers 41, 42 can be further spaced at least to an axial distance corresponding to the width of the forming groove 56, so that the thickened edge contour 3 on the blank 1 significantly by the contour of the mold groove 56th the compression roller 50 is formed.

In the FIGS. 3 and 4 is illustrated that during radial compression an outer diameter of the blank 1 decreases, at the same time a thickened edge contour 3 is formed along the outer edge.

A final phase of the shaping of the thickened edge contour 3 with the compression roller 50 and the two axial forming rollers 41, 42, is shown schematically in FIG Fig. 5 shown. Fig. 5 It can also be seen that an outer profiling 14 is provided on an outer side of the spinning chuck 12. In the illustrated embodiment, the outer profile 14 is designed as an axial keyway.

By means of one or more compression rollers 50, the outer edge of the blank 1 with the thickened edge contour 3 can be axially transferred to the outer profile 14 of the spinning chuck 12, as shown schematically in FIG Fig. 6 is shown. For this purpose, the upset roll 50 according to the invention is provided with the molding groove 56 with an edge-side pressing region 60 in addition to the central swaging region 54. At the pressing portion 60, a radially projecting nose 62 is provided with a pressure radius, which merges on the one hand in an inlet slope 64 and on the other hand in a discharge slope 66. Furthermore, the upset roller 50 according to the invention can also have an opposite end-pressing region 70, with which a front side of the workpiece to be formed can be processed. Alternatively or additionally, a further flow-forming roller 30 can be delivered to the periphery of the workpiece for folding.

In the illustrated embodiment, for the final forming of the Umformteiles 9 finally according to the illustration of Fig. 7 still a frontal profile 16 are formed. For this purpose, the compression roller 50 can be delivered to a front side of the Umformteiles 9 with a forehead-pressing portion 70. The only schematically indicated upset roller 50 has in the end-pressing region 70 on a projecting, approximately rectangular pressing edge.

Upon completion of the final forming step, the forming member 9 is ejected from the spinning chuck 12 by means of a slidable annular ejector 90 and removed. The forming part 9 may be a clutch disk carrier for an automatic transmission. Then, to form another workpiece, a new round blank 1 can be delivered to the device 10 and clamped between the spinning chuck 12 and the counter-holder 20.

Claims (13)

Method for producing a forming part (9) from a blank (1), in which - The blank (1) is set in rotation and at an outer edge of the blank (1) at least one compression roller (50) is radially delivered, which has a circumferential shaping groove (56), - The outer edge of the blank (1) is compressed to a thickened portion which is formed according to the forming groove (56) of the compression roller (50) to a thickened edge contour (3), and - At the radial upsetting to an outer region of the blank (1) laterally at least two axial forming rollers (41, 42) are switched on or delivered, which participate in forming the opposite edge contour (3), characterized, - That the two axial forming rollers (41, 42) at least in an initial phase of the radial compression to the thickened region with an axial forming distance to each other be delivered, which is smaller than an axial width of the forming groove (56) of the compression roller (50), wherein the thickened area is axially backpressed. Method according to claim 1,
characterized,
Toggle that the at least two axial forming rollers (41, 42) immediately behind and / or in front of the compression roller (50) or be delivered. Method according to claim 1 or 2,
characterized,
that the two axial forming rollers (41, 42) be adjusted axially during upsetting each other. Method according to one of claims 1 to 3,
characterized,
that the two axial forming rollers (41, 42) are radially adjusted during the upsetting. Method according to one of claims 1 to 4,
characterized,
that in an end phase of the radial compression, the axial forming rollers (41, 42) are spaced from the thickened region and the thickened region is finally shaped by the at least one compression roller (50) to the edge contour (3). Method according to one of claims 1 to 5,
characterized,
that in the same clamping of the blank (1) an outer edge with the molded thickened edge contour (3) on a spinning chuck (12) folded and a peripheral wall portion (8) is formed. Method according to claim 6,
characterized,
that the transfer is carried out by means of the at least one compression roller (50). Method according to claim 6 or 7,
characterized,
that during thickening the thickened edge contour (3) is formed in an outer profile (14), in particular a keyway profile or a toothing, which is formed on the spinning chuck (12). Upset roller, in particular for carrying out a method according to one of claims 1 to 8,
with a roller main body (52) having an upsetting region (54), which has a circumferential shaping groove (56) for compressing and forming a peripheral region of a circular blank (1),
characterized,
in that at least one radially projecting pressing region (60) is additionally provided, which is designed for pressing and / or pressure-rolling. Upset roller according to claim 9,
characterized,
in that the swage region (54) is arranged in an axial center section and the pressing region (60) is arranged in a lateral edge section of the roller main body (52). Upset roller according to claim 9 or 10,
characterized,
in that the pressing region (60) has a radially projecting nose (62) with a pressing radius and an inlet and / or outlet slope (64, 66) in cross-section. Device for producing a formed part from a blank (1), in particular according to a method according to one of claims 1 to 8,
with a drive device for rotationally driving a blank (1) and with at least one compression roller (50) which can be radially fed to the blank (1) for compressing the outer edge of the blank (1),
characterized,
in that a compression roller (50) according to one of claims 9 to 11 is provided. Device according to claim 12,
characterized,
in that for clamping the round blank (1) a spinning chuck (12) is provided, on which an external profiling (14) is formed, on which an edge section of the blank (1) can be transferred to form a forming part (9) with internal profiling.

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