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US3837200A - Apparatus for making sheet metal pulleys - Google Patents

Apparatus for making sheet metal pulleys Download PDF

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Publication number
US3837200A
US3837200A US00224778A US22477872A US3837200A US 3837200 A US3837200 A US 3837200A US 00224778 A US00224778 A US 00224778A US 22477872 A US22477872 A US 22477872A US 3837200 A US3837200 A US 3837200A
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United States
Prior art keywords
blank
groove
die
pulley
wall
Prior art date
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US00224778A
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English (en)
Inventor
F Wolbert
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Arrowhead Engineering Corp
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Arrowhead Engineering Corp
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Filing date
Publication date
Application filed by Arrowhead Engineering Corp filed Critical Arrowhead Engineering Corp
Priority to US00224778A priority Critical patent/US3837200A/en
Priority to DE2304452A priority patent/DE2304452A1/de
Priority to GB476073A priority patent/GB1415595A/en
Priority to CA163,223A priority patent/CA977624A/en
Priority to BR73998A priority patent/BR7300998D0/pt
Priority to JP48015761A priority patent/JPS4892264A/ja
Priority to FR7304777A priority patent/FR2171419B1/fr
Priority to US05/489,992 priority patent/US3935627A/en
Application granted granted Critical
Publication of US3837200A publication Critical patent/US3837200A/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/021—Deforming sheet bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D15/00—Corrugating tubes
    • B21D15/04—Corrugating tubes transversely, e.g. helically
    • B21D15/10—Corrugating tubes transversely, e.g. helically by applying fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/021—Deforming sheet bodies
    • B21D26/025—Means for controlling the clamping or opening of the moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/021—Deforming sheet bodies
    • B21D26/027—Means for controlling fluid parameters, e.g. pressure or temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/26—Making other particular articles wheels or the like
    • B21D53/261—Making other particular articles wheels or the like pulleys
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16H—GEARING
    • F16H55/00—Elements with teeth or friction surfaces for conveying motion; Worms, pulleys or sheaves for gearing mechanisms
    • F16H55/32—Friction members
    • F16H55/36—Pulleys
    • F16H55/44—Sheet-metal pulleys
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49453—Pulley making
    • Y10T29/4946—Groove forming in sheet metal pulley rim

Definitions

  • Apparatus for forming a sheet metal pulley from a hator cup-shaped blank having an outwardly extending flange includes a die having a seat upon which the blank rests, and a seal between the seat and flange. A fluid conduit conducting fluid to the interior of the blank. Pumps and valves providing a predetermined and adjustable pressure and volume of fluid within the blank during formation of a pulley. Segmented forming dies, reciprocable laterally of and relative to the blank, engaging the flange of the blank on the side remote from the seal to effect the seal and defining the pulley groove remote from the hub.
  • the segmented forming dies carry and provide guiding means for vertical movement of intermediate forming dies, which are displaced vertically toward the flange by engagement by and with the ram.
  • This invention relates to new and improved single and multigroove sheet metal pulleys such as are used in automobiles and similar and related applications.
  • This invention also relates to a new and improved method and apparatus for forming the grooves in such new and improved single and multigroove sheet metal pulleys from a cup-shaped blank in a single, continuous step without handling, displacement or relocation of the blank during formation of the pulley grooves.
  • this invention relates to a new method or process for forming the grooves in new and improved single and multigroove pulleys, in which the groove(s) are formed and at least one wall of a groove is shaped, folded double or crimped, in a single step from a drawn blank, by the use of external, mechanical force and internal fluid of selectively adjustable volume and pressure, sequentially controlled so that external pressure and motion is exerted on the blank during groove formation and the changing volume and pressure and support, within the blank, together with the location, sizing and closing of the spacing surrounding the blank determine the position and size of the grooves, respectively, and the flow and working of the metal of the blank by and from which the grooves are.
  • this process comprises stamping and drawing a piece of sheet metal to form a cup-shaped blank having an external flange at the open end and distorting the blank, by means of axial and radial or lateral pressure exerted by compacting a deformable rubber mass, to displace or bulge the adjacent portion of the blank outwardly and then, as a separate step, after the rubber mass has regained its original shape and been removed, upsetting or exerting an axial pressure on said blank, to bend or collapse said bulge into a compact flange. Additional flanges and grooves were formed in the same way with the blank being moved or relocated to a different press for the formation of each separate groove (flange). Sizing and finishing were accomplished on still other apparatus including appropriate sizing rolls after the grooves were formed by the multistep process just described.
  • each groove in this latter process was formed separately and the mandrels were retracted away from the pulley after each groove was formed in order to be positioned for formation of the next groove.
  • working and thinning of the metal could be minimized, but not eliminated, by collapsing the blank axially as the interior rollers or segments expanded to form the bulge.
  • the interior rollers or segments were retracted before the bulge was collapsed to form the wall of the pulley groove.
  • both the rollers and the blank were rotated.
  • Still another prior art process is to split a round, flat blank having a thick edge by forcing a circular rotating tool into theedge intermediate the thickness of the blank to form a single groove pulley.
  • Multigroove pulleys were built up by welding alternate spacers and similarly formed single groove structures together.
  • Another object of this invention is to provide new and improved, single and multigroove sheet metal pulleys which are uniform in structure and quality; which are efficiently and economically manufactured and used; which include at least one groove having at least one folded or crimped wall; and which are formed by means of a single-step, continuous method and in an apparatus which provides repeatability whereby successive pulleys, which are to be of the same size and characteristics, have a groove or grooves which are essentially duplicates of each other and the same in structure.
  • Still other objects of this invention include the provision of a new and improved process and new and improved apparatus for providing a new and improved single or multigroove sheet metal pulley which includes new and improved means for confining a forming fluid within a blank for making single and multigroove pulleys; which utilizes a forming fluid disposed within the blank, but requiring no other container; and which includes new and improved means for effecting a seal between a blank and a forming die to retain fluid and fluid pressure within the blank.
  • Still further objects of this invention include the provision of a new and improved process for forming the grooves in single and multigroove sheet metal pulleys for automotive and other industrial uses and applications which comprises a single step; which forms the pulley groove or grooves from a one-piece blank without requiring intermediate handling thereof; which utilizes a hollow blank and maintains and protects the blank against undesirable collapse and the metal thereof against undesired internal flow, buckling, drawing, thinning, or the like, by fluid and fluid pressure disposed and exerted within the blank; which has new and improved method and means for sealing the edges of the blank to prevent fluid and fluid pressure from escaping therefrom; which flows and distorts the metal of the blank along predetermined paths and to and into predetermined, single or multigroove configuration in a single step; which is useful for forming grooves in an individual pulley which are of the same or different diameter and/or the same or different pitch; and which utilizes a relatively low internal pressure or force which need be only sufficient to prevent-internal collaps
  • a still further object of this invention is to provide new and improved apparatus for forming the groove or grooves in single and multigroove pulleys embodying this invention and to provide such apparatus having new and improved means for containing a forming fluid within the blank and new and improved means effecting a seal with the blank from which the pulley is formed.
  • a still further object of this invention is to provide a new and improved single or multigroove sheet metal pulley, a new and improved process for making the same and new and improved apparatus for making single and multigroove sheet metal pulleys, each of which obtains one or more of the objects and advantages set forth above.
  • FIG. 1 is a vertical sectional view of a new and improved pulley embodying this invention and having grooves made in accordance with the method of this invention on apparatus embodying this invention.
  • FIG. 2 is a vertical sectional view of a blank from which the pulley of FIG. 1 is formed.
  • FIG. 3 is a vertical sectional view of another pulley embodying this invention and also made in accordance with the method of this invention on apparatus embodying thisinvention.
  • FIG. 4 is a vertical sectional view of a blank from which the pulley of FIG. 3 is formed.
  • FIG. Si is a schematic, vertical sectional view illustrating the blank of FIG. 2 positioned in apparatus embodying this invention for processing in accordance with the method of this invention, prior to groove formation.
  • FIG. 6 is a schematic vertical section similar to FIG. 5 illustrating a stage in pulley groove formation, according to the method of this invention, wherein the bulge defining the upper wall of the first groove is being formed.
  • FIG. 7 is a view similar to FIG. 6 illustrating s subsequent stage of said method, wherein the wall of the first groove is being folded or crimped.
  • FIG. 8 is a view similar to FIG. 7 illustrating a subsequent stage of said method wherein the bulge defining the second groove is being formed.
  • FIG. 9 is a view similar to FIG. 8 illustrating a subsequent stage of said method wherein the wall of the second groove is being crimped.
  • FIGS. 10-13, inclusive, are views similar to FIGS.
  • FIG. 14 is a vertical sectional view of another pulley embodying this invention which is made in accordance with the method of this invention on apparatus embodying this invention from a blank as in FIG. 4.
  • FIGS. 15-18, inclusive are schematic sectional views showing apparatus embodying this invention and different stages in the process of this invention during the formation of a pulley as shown in FIG. 14.
  • FIG. 19 is a diagrammatic view illustrating the hydraulic system of apparatus embodying the invention for controlling the movement of the apparatus.
  • FIG. 20 is a diagrammatic view illustrating the system for controlling the pulley-forming fluid.
  • a pulley embodying this invention is indicated generally at 1, FIG. 1, and is depicted as a two-groove pulley in which the grooves are of different diameter (ball diameter) but have the same pitch or width. It is to be understood, however, that pulleys embodying this invention may have a greater or lesser number of grooves than pulley 1, may have grooves, if multigrooved, of the same or different diameters and/or of the same or different pitch or width.
  • Pulley l is particularly adapted for use in automotive application in connection with automobile engines, fans, crankshafts, and the like, although such pulleys may be used in other industrial applications or wherever a low cost, but balanced, concentric, uniform and efficient pulley is useful or desirable.
  • Pulley l is formed of sheet metal and is distinguished not only by the fact that it is formed by the onestep, continuous process of this invention from a blank without need for relocation or resetting of the partially formed pulley during formation, but, also, by the fact that it is of sufficiently low cost and uniform standard to be practical for mass production as original equipment for automobiles and similar mass-produced items.
  • Pulley l is made in apparatus, indicated generally and schematically at 2 in FIGS. 5-9, inclusive, and by the method illustrated in FIGS. 5-9, inclusive. Said apparatus 2 and method produce pulleys having the structure, characteristics and function of the pulley l as described herein.
  • Apparatus 2 comprises a plurality of dies and holders therefor, indicated generally at 3, generally referred to herein as die(s) and to be hereinafter more fully described.
  • Dies 3 are mounted in a conventional press, indicated generally at 4, FIGS. 5-9, inclusive. Dies 3 are adapted to be moved (slid and reciprocated) linearly in the matter and sequence described below, by hydrauliccylinders or motors, not shown, in accordance with methods of actuation and displacement or movement which are well-known in the art, do not form part of the present invention and need not be and are not further described herein.
  • Pulley l is formed from a blank 5, see FIG. 2, which is drawn and prepared in a conventional way in appara- [us not shown.
  • Pulley 1 includes a transverse, horizontal as viewed, hub portion 6, FIG. 1, a first (hereinafter sometimes called inner) groove 7 having sides or walls (inner and outer, respectively, relative to the hub 6) 8 and 10, respectively. Pulley 1 also includes a second (hereinafter sometimes called outer) groove 11 having sides or walls (inner and outer, respectively, relative to the hub 6) 13 and 14, respectively.
  • Pulley 1 also, conveniently and preferably includes an axially extending flange portion 16, remote from the hub, which stiffens the completed pulley.
  • the inner sides or walls 8 and 13 of the grooves 7 and 11, respectively, are folded or crimped, as shown, during the process of forming pulley l and, as such, add strength and rigidity to the pulley:
  • the groove 7 is spaced from the hub by an axially extending wall portion 17, and the grooves 7 and 11 are spaced apart by an axially extending wall portion 18. Further, as shown, the grooves 7 and 11 are of different diameters (ball diameters) and the same width. It is to be understood, however, that pulley 1 could embody a greater or lesser number of grooves, that the grooves may be of the same or different diameters; that the grooves may be of the same or different widths and that the grooves may be juxtaposed to each other and/or the hub, respectively, or spaced apart a greater or lesser distance than shown, all within the scope and objects of this invention.
  • pulley 1 is formed from blank 5, FIG. 2.
  • Blank 5 is ofa stepped cup-shape and includes a horizontal hub portion 22 which becomes the hub portion 6 of the pulley l, a first axially extending wall portion 23, which forms the wall 17 of pulley 1, a first angular, transverse portion 25, which locates the axial position of the inner side or wall 8 of the inner groove 7, a second axially extending wall portion 26 which forms the inner side or wall 8 of the inner or first groove 7, a second angular, transverse portion 27 (low pitch, conical surface), which locates and forms the outer wall 10 of the inner groove 7, a third axially extending wall portion 28 which forms the wall portion 18 and the inner side or wall 13 of the outer groove 11, a third angularly disposed surface 30, which forms the outer side or wall 14 of the outer groove 11, and a fourth axially extending wall portion 31 which forms the flange 16 of the pulley l.
  • the process of this invention comprises a continuous, single step, sequential stage process wherein pulley l is formed from blank 5 by a continuous displacement of the metal of the blank into the desired shape, i.e., by bulging, crimping and groove formation, the continual or substantially continual mechanical displacement of the dies 3 of the apparatus in predetermined order and sequence while continuously coordinating and adjusting the volume of liquid within the blank, and holding, or changing, but always controlling, the pressure thereof, so as to control, internally, the shaping and displacement of the metal in the blank.
  • the dies 3 are mounted on a conventional press and are actuated to reciprocate by hydraulic cylinder(s) or motor(s) (not shown) in the usual way. It is a feature of this invention, in its preferred form, that all of the forming dies move or are displaced in an axial direction during formation of the pulley, although those die segments which shape the interiors of the respective grooves are also mounted on the press for radial reciprocal motion, as well, so that they may be withdrawn from the completed pulley.
  • the movable exterior dies necessary to form the pulley 1 are indicated specifically at 33, 34 and 36, respectively, and the movable interior die is indicated at 37 and they are conveniently mounted on and move with holders 33h, 34h and 36h, respectively, and die and holder are generally referred to hereinafter by the term die which contemplates both the die and the holder whether formed as integral or multipiece units.
  • Die or ram 33 reciprocates axially relative to the blank and pulley and is displaced selectively upwardly and downwardly by the aforementioned hydraulic cylinder or motor to and for the purpose and in the sequence to be hereinafter more fully described.
  • Dies 34 and 36 are segmented, conveniently in three parts.
  • the segments of die 34 are carried on the respective segments of lower die 36 and are displaced or reciprocated radially or horizontally with the lower die 36.
  • the segments of die 34 are biased upwardly, as viewed, by springs 38 into the relative position shown in FIG. 5.
  • Die 34 is forced or slid downwardly, as viewed, on the posts of pins 39, which are supported on die 36, by the laterally extending flange or lip 40 on the upper die 33.
  • Flange 40 engages the intermediate die 34 as the upper die or ram 33 is displaced downwardly.
  • Lower die segments 36 are reciprocable radially, as noted above, and when so reciprocated carry the die segments 34, respectively, in the same motion.
  • Press 4 includes a table 42 and a base 43.
  • a cylindrical block or fixed die 45 is mounted on table 42 by suitable means, such as screws 46.
  • Die 45 supports the blank when the same is positioned in the press.
  • die 45 includes a shaped upper end, as viewed, indicated generally at 48, having an angularly disposed top portion or surface 50 which complements in size and shape the third angular transverse wall portion of blank 5 to the end that surface 50 supports the lower or exterior part of the outer side or wall 14 of outer groove 11.
  • the upper end 48 of die 45 also includes a vertical or axial wall portion 51 which fits inside the fourth axially extending wall portion or flange 31 of the blank 5.
  • the angle between surfaces 48 and 51 of die 45 is the same or substantially the same as that desired in the finished pulley l and formed preferably in the blank 5 so that die 45 both supports and centers the blank 5 in the apparatus 2.
  • Die 45 may be further stepped, as at 53, to provide for increased thickness and strength as necessary and desired.
  • the interior surface 54 of die 45 is cylindrical and finished smooth for coaction with and support of the interior die 37, as will more fully appear.
  • the surface 50 includes a continuous sealing means 56 for engaging and sealing in fluidtight relationship against the adjacent side or surface of blank 5.
  • the sealing means 56 is essentially fluidtight within the pressures experienced or used in forming the pulley 1 from blank 5 to the end that none or substantially none of the forming fluid or liquid can escape from the interior of the blank 5 between die 45 and blank 5.
  • sealing means 56 preferably comprises an O-ring or gasket 57 disposed in a suitably shaped groove 59 formed in the surface 50 of die 45.
  • the depth of groove 59 is somewhat less than the axial thickness of gasket 57 to ensure effective sealing engagement between the gasket 57 and surface 60, FIG. 2, of blank 5 while not preventing proper load bearing engagement between surfaces 60 and 50.
  • Die 37 is cylindrical and has a close sliding fit with the interior surface 54 of die 45.
  • Die 37 is adapted to reciprocate longitudinally, vertically, as viewed, relative to the axis of the blank and pulley when the same are within the apparatus 2.
  • die 37 has an upper, as viewed, horizontal surface 63 and an axially extending surface 65.
  • die 37 also includes an angularly extending surface 67 between the axial vertical wall portions or surfaces 65 and 68, respectively.
  • Surface 67 is of a dimension equal to the distance between the interior surfaces of walls 23 and 28 with the angle between surfaces 67 and 68 of die 37 being the same as the interior angle between wall portions 27 and 28 of blank 5.
  • Die 37 is preferably and conveniently provided with one or more sealing rings 70 located in its lateral periphery so as to coact in the usual manner with surface 54 of die 45.
  • Die 37 is reciprocated by suitable means.
  • the lower end 80, as viewed, of die 37 is preferably and conveniently formed at a bias with a slot, track or groove 81 therein.
  • a complementary wedge 83 with a tongue 84 for coaction with groove 81 is also provided and die 37 is supported thereupon.
  • Hydraulic cylinder or motor means shown schematically at 86, reciprocates wedge 83 transversely, as viewed. As wedge 83 is moved rightwardly, as viewed, by cylinder 86, it lifts die 37 and as it is moved leftwardly it lowers the die.
  • the pitch of wedge 83 is, of course, sufficient to move the ram the distances and in the sequence required by the process of this invention to be hereinafter more fully described.
  • inner die 37 also includes a plurality of tubes or conduits and 91, respectively, which provide communication laterally of the die 37 through the surface 68 and a tube 93 which provides communication with the space S above die 37 and within blank 5.
  • tube 93 also preferably includes means whereby air may be evacuated from the top of space S adjacent the interior of the hub 22 of blank 5 as the oil or liquid flows into the said space.
  • tube 93 is counterbored at its top as at 94 and a spring-biased extension tube, indicated generally at 96, is disposed therein.
  • Extension tube 96 includes a central tube portion 97 and a base 99 having a close sliding fit with the wall of the counterbore 94. Extension tube 96 is biased outwardly, upwardly as viewed, by spring 100 and is retained within counterbore 94 by a snap ring, pin or other suitable means, not shown.
  • Tube portion 97 extends outwardly from the open end of tube 94 a sufficinet distance to provide an air release or escape for the space S above die 37 so that the space can be filled with liquid.
  • Extension tube 96 telescopes within tube 93 so that the die 37 may be seated fully within blank 5 and against the inside of hub 22.
  • Notches 102 at the end of tube portion 97 permit flow of air into the tube portion even when the tube rests against the inside wall of hub 22 of the blank 5.
  • a vacuum pump may be interconnected with tube 93 to speed the evacuation of air from the space S.
  • FIG. depicts the apparatus 2 shortly before pulley formation by the process of this invention is begun.
  • the blank 5 is positioned on die 45 and is gripped by die 36.
  • Die 34 is in its upper or extended position, as shown, die or ram 33 has been lowered into contact with the hub 22 of blank 6 and die 37 is moving upwardly so as to engage surface 67 against the interior surface of wall portion 27.
  • FIG. 6 shows a later stage in the process of this invention wherein a quantity of oil (liquid) has been introduced into the space S above the die 37 and within the blank 5 through tube 94 which was thereupon connected with an exhaust port, not shown, so that the air above the oil could be exhausted via tube portion 97 as die 37 continued to move upwardly until, as shown, surface 67 had seated against the wall portion 27 of blank 5, at which time the space S was completely full of oil.
  • Ram 33 had then continued its descent until the position shown in FIG. 6 was reached.
  • Wall portion 28 remained straight, as shown, or buckled or bulged outwardly only slightly as engagement between surface 67 and the interior of wall portion 27, the bends in the blank and the engagement of the surface 54 of die 37 with the wall portion 28 of blank 5 all function together to prevent any deleterious transmission of force and/or bulging of the wall portion 28.
  • a valve controlling tube 93 is then actuated in response to the distance traveled by ram 33, time elapsed, or pressure within the space S resulting from the movement of ram 33 and the oil flows from space S via tube 93.
  • Ram 33 continues its descent and crimps the wall portion 26, as shown in FIG. 7, to form the inner wall 8 of inner groove 7.
  • Wall portion 26 is crimped by being squeezed between ram 33 and the surface 101 of die 34. While the oil continues to flow from the space S until the space is fully or substantially fully evacuated and the crimp to form wall 8 is completed, as shown in FIG. 7. And, of course, as shown in FIG. 7, the extension tube 96 has been telescoped by ram 33 into the tube 93.
  • valves or controls are actuated to permit fluid to be pumped through conduits 90 and 91 against the wall portion 28 of blank 5 which bulges, as shown in FIG. 8, under the effect of the collapsing (downward, as viewed) force of ram 33 and die 34 (die 34 now being displaced downwardly by the engagement of flange 40 of ram 33 therewith) and the outward pressure of the oil laterally ofdie 37, which is preferably retracted (lowered) at the same rate as ram 33 descends so that the relationship between ram 33 and die 37 remains constant as the new bulge is being formed.
  • valves and controls are actuated to permit flow of oil from the space surrounding die 37 and within the bulge in wall portion 28.
  • the continued movement of the ram 33 and dies 34 and 37 then crimps and forms the inner wall 13 of the lower groove 11 between the surface 102 of die 34 and the die 36, as shown in FIG. 9.
  • Pulley 1 is shown in its completed form in FIG. 9 with the process of this invention completed.
  • pulley 1 Once formation of pulley 1 is completed, as in FIG. 9, the movable dies are withdrawn, the pulley removed, a new blank positioned, and the cycle is repeated.
  • FIGS. 10-13, inclusive depict stages of the process of this invention forming the pulley 1 shown in FIG. 3 in which the grooves are of the same diameter and width.
  • FIGS. 10-13 like numbers refer to like parts and portions as in FIGS. 5-9, inclusive, and the FIGS. 10-13 show stages in the groove formation in a manner similar to FIGS. 5-9, inclusive, and prime numbers refer to similar parts and portions modified because of the different shape of pulley 1 viz-a-viz pulley l.
  • Pulley 1' has inner and outer grooves 7 and 11, respectively, which are of the same diameter and size. Pulley 1' is formed from blank 5', FIG. 4, with both the inner and outer grooves 7' and 11' being formed from wall portion 28'. More particularly, the outer wall 10 of inner groove 7' and the inner wall 13 of outer groove 11' are all formed from axial wall portion 28 of blank 5', whereas the inner side of inner wall 8 is formed by angular wall portion 25 of blank 5 and the outer wall 14' of outer groove 11 is formed by angular wall portion 30 of blank 5.
  • the dies 33, 34 and 36', respectively, in FIGS. 10-13, inclusive, are, of course, changed, viz-a-viz dies 33, 34 and 36, respectively, in FIGS. 5-9, inclusive, to be appropriate for the grooves of pulley 1 instead of pulley 1.
  • the die carriers remain the same.
  • FIG. 10 shows the apparatus prior to groove formation, as the inner die 37 is being displaced upwardly to position the end 62 thereof against the hub 22.
  • the die 36 has gripped the wall of blank 5 with seal 56' preventing escape of fluid from between the surface 50 of die 45 and the lower surface 107 of angular portion 30 of blank 5.
  • the air is evacuated from the space between the top 62 of die 37 and the hub 22 of blank 5' until the die seats against the hub.
  • the ram 33 is shown positioned against the blank before the die 37, it is to be understood that the die 37 could be positioned first or even that the die could be so located,
  • a forming fluid such as oil is forced through the conduits 90 and 91 at the same time downward movement of the ram 33 is initiated or continued, if the apparatus has been timed so that the descent (motion) of ram 33 need not be halted while the air is evacuated from within the blank and die 37 is positioned against the hub.
  • the movable dies are then retracted, the completed pulley 1' is removed and the cycle repeated, as desired.
  • Pulley 1 is similar to pulley 1 in FIG. 3 except that in this instance, while the grooves are of the same diameter, the upper groove, 139 as viewed, is wider and has a flat bottom portion 141.
  • Pulley l is formed from a blank having the same shape as that in FIG. 4, but having a greater axial length at wall portion 28'.
  • FIGS. 14-18, inclusive refer to the same parts and portions as in FIGS. 3, 4 and inclusive.
  • the single-step process depicted in FIGS. -18, inclusive is similar to that depicted in FIGS. 10-13, inclusive, utilizes the same one-step continuous motion, i.e., continuous displacement of the ram process as depicted in FIGS. 5-9 and 10-13, both inclusive, respectively.
  • the inner die 37 remains stationary and could, therefore, be formed as a part of die 45, if desired.
  • the bulging and groove formation is accomplished in the same order and manner as is depicted in FIGS. 10-13, inclusive, except that the bulging, crimping and wall and groove formation is controlled by the movement of the external dies and ram 33 plus control of the internal volume and pressure of liquid within the blank 5" and above and about the upper (as viewed) end of the die 37.
  • the process of this invention is a continuous, single-step process.
  • a relatively large axial pressure or force is continuously exerted on a blank and the volume and pressure ofa forming fluid, such as oil, within the blank and the movement of the forming dies is controlled to cause the metal to bulge outwardly and then to be crimped between or pressed against the dies to form the groove.
  • the size of the bulge is controlled by controlling the release of the fluid within the blank so that the dies which cause the bulging also shape and form the grooves and the walls thereof as set forth.
  • the pressure of the fluid is also controlled so that metal flow is always in the desired direction and the fluid volume is controlled, in part, as noted, in response to changes of pressure thereof, as by releasing fluid to reduce the volume thereof, once the bulge is formed and crimping is to begin to reduce the interior volume of the blank to be consistent with the volume thereof to exist after a wall is crimped or otherwise formed.
  • FIG. 19 depicts diagrammatically suitable hydraulic system for use in and for operating apparatus embodying this invention and particularly adapted for carrying out the process as depicted in FIGS. 5-9, inclusive.
  • the hydraulic circuit is, of course, interrelated with a suitable electrical circuit activated by suitable switches, including limit switches, and the like.
  • Mechanical parts, indicated diagrammatically in FIG. 19, are the same as the correspondingly referenced parts, respectively, in FIGS. 5-9, inclusive.
  • reference character 200 indicates the double-acting operating cylinder for the ram 33
  • reference character 201 indicates the double-acting operating cylinder (5) for the carrier (5) which control the movement or reciprocation of the die (5) 36 and the lateral movement of die (5) 34
  • ref erence character 203 indicates the doubleacting operating cylinder which controls the reciprocation of the inner die 37, either by lateral movement of the wedge, as preferred, or by a direct connection with the die, i.e., by having the cylinder in axial alignment with the die and the die connected to or formed as a part of the piston.
  • Oil is supplied to the respective hydraulic cylinders by a suitable motor driven pump (5) through appropriate conduits having valves controlled by suitable timers, or limit or pressure switches.
  • a conventional electric motor 204 is utilized to drive two pumps; one, 206, a high-volume, low-pressure pump for rapid advancement and retraction of the cylinders before and after actual pulley formation, and one, 207, a low-volume, high-pressure pump for advancing the dies (rams) during pulley formatron.
  • Each pump has an intake line 213 and 215, respectively, connected to a sump or reservoir 216.
  • Each pump also preferably has a solenoidoperated unloading relief valve associated therewith, indicated generally at 217 and 218, respectively, which is of standard commercial structure.
  • Discharge or pressure lines 209 and 210 are connected by means of conduits 220, 221 and 222 and solenoid directional control valves 224, 225 and 226, respectively, with the cylinders 200, 201 and 203, respectively.
  • the cylinders 200, 201 and 203 are also connected through the said valves 224, 225 and 226, respectively, with the sump 216.
  • the solenoids position the respective valves to advance or retract the cylinders, and, therefore, the respective dies, in accordance with the process described above.
  • Speed control valves 228 and 229, respectively, are preferably disposed in the lines 221 and 222, respectively, upstream of the respective directional control valve.
  • a check valve 231 is preferably located in the pressure line to cylinder 201 so that the pressure of the ram 33 cannot cause or tend to cause the cylinder (s) 201 to react to withdraw the die 34 and 36 laterally during operation of the ram 33 (cylinder 200).
  • the unloading relief valve 217 permits the lowpressure pump to discharge during actual pulley formation, i.e., while the ram 33 (cylinder 200) is fully loaded and the unloading relief valve 218 permits the high-pressure pump to discharge when the cylinders are at rest and no oil is flowing.
  • the oil lines to and from cylinder 200 and intermediate the cylinder and the control valve 224 preferably also include a conventional regenerative circuit, indicated generally at 232, and functioning on the down stroke to increase cylinder speed by recycling the hydraulic fluid, in part, without returning it through the sump.
  • Limit switches 235, 236, 237 and 238 are disposed to be operated by ram 33 in predetermined sequence and time.
  • Limit switches 241 and 242 are disposed to be operated by wedge 83 on its advancing (raising of die 37) and retracting (lowering of die 37) motions, respectively.
  • Limit switch 243 is disposed to be operated by cylinder 201 as die 34 is retracted to free the completed pulley at the end of the cycle.
  • Switch means is provided to respond when cylinder 201 and, therefore, dies 34 and 36, is in its fully advanced position to signal that a new cycle is commencing.
  • switch means comprises a pressure responsive switch 245 disposed in communication with fluid circuit 246 intermediate directional valve 225 and chamber 248 of cylinder 201.
  • Switch 245 responds to a pressure chamber 248 of sufficient magnitude to ensure that the die segments of dies 34 and 36 are fully seated laterally and will remain so during operation of the ram 33 (cylinder 200) during subsequent pulley formation as described above.
  • valve 225 is in the opposite setting from that shown so as to advance, instead of retract, the piston of cylinder
  • the limit switches and valves, motors, and the like are interconnected by suitable electrical circuits including timer, not shown, to operate in the manner described above in connection with FIGS. 5-9, inclusive, and can be modified, of course, to from in the manner described with respect to the disclosure of FIGS. 10-13, inclusive, and 15-18, inclusive, respectively.
  • valve 224 has an intermediate, neutral position which provides a dwell in the travel of ram 33 after contact is made with hub of blank 5 and before pulley formation is commenced during which air is evacuated ffrom the interior ofthe blank in the manner and for the purpose described above.
  • valves 224, 225 and 226 have been described as solenoid-operated and electrically controlled, it is to be understood that other types of valves and control systems, such as, for example, fluid or air, may be used to control the hydraulic circuits, including the forming fluid or oil circuits, described below.
  • the forming fluid used in this invention is an oil or similar liquid and, also, preferably the volume and pressure thereof is controlled by a separate hydraulic system from that which actuates and controls the rams and dies.
  • FIG. 20 A suitable system for providing and controlling the forming fluid is depicted diagrammatically in FIG. 20 wherein like reference characters refer to like parts as in FIGS. 5-9, inclusive.
  • the forming fluid is forced into the space within the blank and above and about the inner die 37 by means of a pump 250, operated by an electric motor 251.
  • Pump 250 pumps the fluid from a sump 253 through an intake line 254 and thence out through discharge line 256.
  • The'fluid in the discharge line is either recycled through the pressure relief valve 257 into the sump or forced into the space S via the lines 258 and 259 and conduits in ram 37, depending on the position of the solenoid-operated directional valve 261 which is controlled by suitable timer and limit switches in accordance with the teachings of this invention as set forth above.
  • One or more check valves 262 may be disposed in lines 258 and 259 to prevent flow of fluid back into the valve 261 and pump 250.
  • the forming fluid system also includes means for draining the forming fluid from the space S, above inner die 37 and within the blank, and for controlling the pressure of the forming fluid within the said space.
  • the same lines within the die 37 serve both as intake and discharge lines to and from the space S with suitable valves, not shown, interconnecting either the pump for charging the forming fluid or the valves (and pump, if one is used as suggested above, to evacuate the air) for controlling the discharge therefrom and the pressure of the forming fluid therein.
  • the dischargesystem includes a discharge line 265, a check valve 266, a solenoid-operated valve 268 through which large volumes of fluid are discharged to the sump 253 and a second solenoid-operated valve 269 which selectively connects the space S with either a low-pressure relief valve 271 or a high-pressure relief valve 272, both of which also discharge into the sump 253.
  • Valve 268 is operated when the volume of the fluid or oil within the blank is to be reduced quickly and the pressure reduced to zero.
  • Valve 269 is operated to interconnect the low-pressure relief valve 271 in the path between space S and the sump 253 when crimping is being performed and to interconnect the high-pressure relief valve 272 when a bulge is being found or the metal is being forced against the dies to complete formation of groove (s).
  • ram 33 is driven downwardly during actual pulley formation so as to exert a large axial force, 75 tons, for example, whereas the forming oil within the blank is at a relative low pressure, sufficient, about 1,500 to 3,000 psi, to prevent internal collapse of the blank (except when crimping when the pressure is at about 200 psi) but also sufficient to force the metal against the dies 34 and 36 as required by the teachings of this invention.
  • the degree and location of the bulge(s), as well as the force and pressure necessary to initiate formation of the same, is determined by the spacing between the dies, i.e., between 33 and 34, for example.
  • means other than the sealing means acting between the fixed die 45 and the flange of the blank may be used to confine the forming fluid within the blank and above the seals 70 on the inner die 37 or its equivalent, provided such means permits the fluid to change in volume and pressure in accordance with the teachings of this invention and further provided that such means does not get caught within a crimped side of a groove or otherwise interfere with the teachings and precepts of this invention or the operation of the apparatus or method as taught herein.
  • Apparatus for forming the grooves in a sheet metal pulley having outer and inner belt-engaging grooves having outer and inner walls therein from a blank having inner or hub and outer or flange ends with at least one axially extending wall portion therebetween, and a flange, having outer and inner sides, extending radially outwardly from said wall portion at said outer end and defining the outer wall of the outer groove of said pulley, siad apparatus comprising first die means for supporting said blank by engaging said flange on said outer side thereof, means providing a seal between said outer side of said flange and said first die means, first way means, a segmented outer die reciprocable laterally on said first way means, relative to said blank, for defining the belt-engaging surface of the outer groove and for engaging said flange on the inner side thereof to effect said seal, means to actuate said segmented die, ram means reciprocable axially relative to said blank for engaging said blank at said hub end and imposing axial force and continuous motion on said hub end
  • said intermediate die defines the belt-engaging surface of said inner groove and engages said lateral wall of said blank to crimp the same and form the inner wall of said outer groove double and said ram means engages said lateral wall of said blank to crimp the same and form said inner wall of said inner groove double.
  • said first die means includes ring die means for supporting said flange and mandrel means disposed centrally of and reciprocable relative to said ring die means, means for actuating said mandrel means axially for reciprocable movement relative to said hub end of said blank to vary the effective volume within said blank intermediate said ram means, said mandrel means actuating means retracting said mandrel means relative to said hub end of said blank after said inner double wall of said inner groove is formed.
  • said first die means has an axially extending lateral wall for supporting a skirt of a said blank, which extends axially from said flange in a direction away from said hub end.
  • each said groove is located and determined as to size by bulging the said lateral wall of said blank.
  • each said groove is located and determined as to size by bulging the said lateral wall of said blank.
  • each said bulge is initiated by flowing metal into an unconfined space relative to the size of the bulge.
  • said sealing means comprises a circumferential groove of predetermined depth in said first die means and a sealing ring in said groove, and said sealing ring has a thickness in the direction of the depth of said groove greater than said depth of said groove.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • General Engineering & Computer Science (AREA)
  • Pulleys (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
US00224778A 1972-02-09 1972-02-09 Apparatus for making sheet metal pulleys Expired - Lifetime US3837200A (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
US00224778A US3837200A (en) 1972-02-09 1972-02-09 Apparatus for making sheet metal pulleys
DE2304452A DE2304452A1 (de) 1972-02-09 1973-01-30 Metallblechriemenscheibe und verfahren zu ihrer herstellung
GB476073A GB1415595A (en) 1972-02-09 1973-01-31 Sheet metal pulley
CA163,223A CA977624A (en) 1972-02-09 1973-02-08 Method and apparatus for making sheet metal pulleys
BR73998A BR7300998D0 (pt) 1972-02-09 1973-02-09 Polia em chapa metalica processo e aparelho para sua fabricacao
JP48015761A JPS4892264A (pt) 1972-02-09 1973-02-09
FR7304777A FR2171419B1 (pt) 1972-02-09 1973-02-09
US05/489,992 US3935627A (en) 1972-02-09 1974-07-19 Method of making sheet metal pulley

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Application Number Priority Date Filing Date Title
US00224778A US3837200A (en) 1972-02-09 1972-02-09 Apparatus for making sheet metal pulleys

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US05/489,992 Division US3935627A (en) 1972-02-09 1974-07-19 Method of making sheet metal pulley

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US3837200A true US3837200A (en) 1974-09-24

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US00224778A Expired - Lifetime US3837200A (en) 1972-02-09 1972-02-09 Apparatus for making sheet metal pulleys

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US (1) US3837200A (pt)
JP (1) JPS4892264A (pt)
BR (1) BR7300998D0 (pt)
CA (1) CA977624A (pt)
DE (1) DE2304452A1 (pt)
FR (1) FR2171419B1 (pt)
GB (1) GB1415595A (pt)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0002032A1 (de) * 1977-11-17 1979-05-30 Wilhelm Heinrich Schroth Verfahren und Vorrichtung zum Herstellen mehrrilliger Keilriemenscheiben
US4289007A (en) * 1979-12-05 1981-09-15 Dyneer Corporation Apparatus for hydraulically forming sheet metal pulleys
US4297869A (en) * 1979-09-10 1981-11-03 U.S. Industries, Inc. Apparatus for fabricating pulley rims
US5031433A (en) * 1987-05-11 1991-07-16 Sanden Corporation Method and apparatus for manufacturing a pulley
US6675621B2 (en) * 2001-09-10 2004-01-13 General Motors Corporation Plural sheet superplastic forming equipment and process
WO2005039799A1 (en) * 2003-10-24 2005-05-06 Hydroformning Design Light Ab Method and apparatus for supplying fluid

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3201711A1 (de) * 1981-11-12 1983-05-26 Winkelmann & Pannhoff Gmbh, 4730 Ahlen "mehrfach-v-riemenscheibe und verfahren zu ihrer herstellung"
JPS58163538A (ja) * 1982-03-23 1983-09-28 Kanemitsu Doukou Yousetsushiyo:Goushi 板金製ポリｖプ−リの製造方法
FR2744380B1 (fr) * 1996-02-06 1998-08-28 Bas En Basset Soc Ind De Installation pour la fabrication de pieces par hydroflambage
ES2154105B1 (es) * 1997-07-07 2001-12-01 Bas En Basset Soc Ind De Instalacion para la fabricacion de piezas por hidrodeformacion lateral.
DE102004058735A1 (de) 2004-12-06 2006-06-08 BFC Büro- und Fahrzeugtechnik GmbH & Co. Prod. KG Metallband als Einlage für Zier- oder Dichtstreifen

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Publication number Priority date Publication date Assignee Title
US349718A (en) * 1886-09-28 hollerith
US701550A (en) * 1902-01-11 1902-06-03 Standard Oil Co Method of shaping metal receptacles.
US701549A (en) * 1902-01-11 1902-06-03 Standard Oil Co Apparatus for shaping metal receptacles.
US3335590A (en) * 1964-08-07 1967-08-15 Boeing Co Accurate control system for axial load bulge forming
US3394569A (en) * 1966-06-23 1968-07-30 Gen Dynamics Corp Forming method and apparatus
GB1167094A (en) * 1966-11-14 1969-10-15 Paul Etienne Franco Jacquemard Sheet Metal Press.
US3675453A (en) * 1970-05-18 1972-07-11 Karl Marsch Machine and method for making pulley grooves or the like

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Publication number Priority date Publication date Assignee Title
FR1012154A (fr) * 1949-06-18 1952-07-07 Emboutissage Hydraulique Moder Procédé et dispositif d'emboutissage
US3630056A (en) * 1968-07-04 1971-12-28 Pierre Cuq Method and assembly for the production by hydroforming of parts of large size, especially in length

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US349718A (en) * 1886-09-28 hollerith
US701550A (en) * 1902-01-11 1902-06-03 Standard Oil Co Method of shaping metal receptacles.
US701549A (en) * 1902-01-11 1902-06-03 Standard Oil Co Apparatus for shaping metal receptacles.
US3335590A (en) * 1964-08-07 1967-08-15 Boeing Co Accurate control system for axial load bulge forming
US3394569A (en) * 1966-06-23 1968-07-30 Gen Dynamics Corp Forming method and apparatus
GB1167094A (en) * 1966-11-14 1969-10-15 Paul Etienne Franco Jacquemard Sheet Metal Press.
US3675453A (en) * 1970-05-18 1972-07-11 Karl Marsch Machine and method for making pulley grooves or the like

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0002032A1 (de) * 1977-11-17 1979-05-30 Wilhelm Heinrich Schroth Verfahren und Vorrichtung zum Herstellen mehrrilliger Keilriemenscheiben
US4297869A (en) * 1979-09-10 1981-11-03 U.S. Industries, Inc. Apparatus for fabricating pulley rims
US4289007A (en) * 1979-12-05 1981-09-15 Dyneer Corporation Apparatus for hydraulically forming sheet metal pulleys
US5031433A (en) * 1987-05-11 1991-07-16 Sanden Corporation Method and apparatus for manufacturing a pulley
US6675621B2 (en) * 2001-09-10 2004-01-13 General Motors Corporation Plural sheet superplastic forming equipment and process
WO2005039799A1 (en) * 2003-10-24 2005-05-06 Hydroformning Design Light Ab Method and apparatus for supplying fluid

Also Published As

Publication number Publication date
GB1415595A (en) 1975-11-26
BR7300998D0 (pt) 1973-09-25
DE2304452A1 (de) 1973-08-16
JPS4892264A (pt) 1973-11-30
CA977624A (en) 1975-11-11
FR2171419B1 (pt) 1977-09-02
FR2171419A1 (pt) 1973-09-21

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