DE102010053547A1 - Method and device for producing an internally and externally toothed cup-shaped sheet metal part - Google Patents

Abstract

Method for producing an internally and externally toothed pot-shaped sheet metal part, in which the non-toothed pot-shaped sheet metal part is pushed onto a rolling mandrel formed with an external toothing corresponding to the internal toothing of the sheet metal part to be produced and then the outer profile is rolled onto the pot-shaped sheet metal part by the pot-shaped sheet metal part being put together is pressed with the rolling mandrel through a set of profiled rollers that runs parallel to the central axis on the sheet metal part while exerting a radial pressure, whereby the material of the sheet metal part is pressed into the tooth grooves of the rolling mandrel, characterized in that in a single method step in the course of a single press stroke (opening and downward movement of the rolling mandrel) the longitudinal grooves in the sheet metal part are finished.

Description

The invention relates to a method and an apparatus for producing an internally and externally toothed cup-shaped sheet metal part according to the preamble of claim 1.

Such a method and a device suitable for this purpose is, for example, with the subject matter of WO 2009/124534 A2 known. In this known method, the toothless cup-shaped sheet metal part is pushed onto an outer toothing formed with one of the internal teeth of the sheet metal part rolling roll and then rolled the outer profile on the cup-shaped sheet metal part by the cup-shaped sheet metal part together with the rolling mandrel by a parallel to the central axis on the sheet metal part is pressed under exercise of a radial pressure rolling profile roller set, whereby the material is pressed into the tooth grooves of the profile mandrel. The content of this document is intended to be fully encompassed by the present invention.

In this known method, the rolling tool consists of a plurality of uniformly distributed on the circumference arranged profile rollers, wherein the arranged for producing the teeth of the sheet metal part in different planes profile roller sets must be used.

With an upper profile roller set a preforming of the longitudinal grooves is exerted in the sheet metal part and the preformed sheet metal part is then either moved to another Rollumformwerkzeug and finally rolled there, or there are several sets of rollers arranged vertically one above the other, one set of rollers preforming and the other set of rollers Finished forms of the tooth grooves of the toothed sheet metal part performs.

Disadvantage of the known method is that the tooth shape of the sheet metal part must be produced in different operations, which is associated with a high workload.

Another disadvantage is that differently shaped profile rollers in the form of different profile roller sets must be used, which greatly increases the cost of such Rollumformwerkzeug.

In the prior art, it is known to form the profile rollers symmetrically, which means that the deforming lateral surface (rolling circumference) of the profile roller is formed absolutely symmetrical. It is a mirror symmetry to the longitudinal center axis, as for conventional profile rollers in the 5a and 5b of the present application. The profile rolls shown there 40 and 41 belong to the state of the art.

Characteristic of this prior art is that with the conventional profile roller 40 according to 5a and the central roll collar formed there, a first forming of the Längsprofilnut is carried out in the sheet metal part, while arranged in the working direction behind it or arranged in another tool, the second conventional profile roller 41 and its smooth shoulder band 19 the final shaping of the Längsprofilnut is made in the sheet metal part.

The invention is based on the object, a method and an apparatus of the type mentioned in such a way that with less use of tools, preferably with only a profile roller set, a finished molding of the longitudinal grooves in the sheet metal part is possible without different profile roller sets with differently shaped Profile roles needed.

To solve the problem, the invention is characterized by the technical teaching of claim 1.

An essential feature of the invention is that in a single process step in the course of a single press stroke (up and down movement of the rolling mandrel), a finished shaping of the longitudinal grooves in the sheet metal part takes place.

With the given technical teaching, there is the significant advantage that it is no longer necessary to first perform a preforming and then a final shaping of the longitudinal grooves in the sheet metal part, but that in the course of a single press stroke (downstroke and subsequent upstroke) a final Forming the longitudinal grooves in the sheet metal part is possible for the first time.

This means that only a single profile roller set is needed to allow a final shaping of the longitudinal grooves in the sheet metal part, which was previously unknown.

According to the invention eliminates the preforming and the final shaping of the longitudinal grooves in the sheet metal part with different profile roles and it is only a single profile roller set used to allow during a downward and an adjoining upward stroke of a rolling mandrel final shaping of the longitudinal grooves in the sheet metal part.

The invention provides in a development of the present invention, that in addition to the final shaping of the longitudinal grooves in the sheet metal part, a calibration followed.

Such a calibration can be carried out, for example, by a calibration ring which penetrates with its calibration teeth and with its calibration base into the already formed longitudinal grooves of the sheet metal part and moves longitudinally along, so as to provide for the production of a final dimensional accuracy. The calibration is in the tenths of a millimeter range and is not comparable to preforming and final molding in the prior art.

It should be noted that calibration is not essential, but it is preferred to obtain such a calibration for obtaining particularly dimensionally stable sheet metal parts.

To achieve the task of achieving a final shaping of the longitudinal grooves of the sheet metal part with a single profile roller set and the profile rollers arranged there, asymmetrical profile rollers are used instead of mirror-symmetrical profile rollers. All asymmetrical profile rollers are rotatably mounted on respective axle and distributed uniformly around the circumference and thus form a single profile roller set, which is intended for the final formation of the longitudinal grooves of the sheet metal part.

As a counterhold for the asymmetrical profile rollers, a rolling mandrel is used, which penetrates into the interior of the cup-shaped sheet metal part and the longitudinal grooves supported from the inside, so that the asymmetric profile rollers penetrate with their associated roller collars and shoulder collars in the associated identically profiled recesses in the region of this rolling mandrel and there lead to a deformation of the sheet metal part. Thus, the sheet metal part is radially inwardly directed by the asymmetric profile rollers arranged outside in the direction of the radially outwardly directed rolling mandrel, wherein the rolling mandrel shape substantially corresponds to the later profile shape of the longitudinal grooves of the sheet metal part.

The invention will now be described in more detail with reference to the drawings. Here are the drawings and their description further advantages and features that are claimed in individual position, but also in combination with each other as essential to the invention.

Show it:

1 : A perspective view of the profile roller set with the calibration ring underneath.

2 : Cutting through a tool in a working condition with the tool in the upstroke again.

3 : Section through the roller forming tool with the calibration ring visible underneath.

4 : An enlarged view 3

5a and b: the two profile rollers according to the prior art.

5c : the novel profile roll according to the invention.

6 : an enlarged schematic diagram of asymmetric roll forming.

7 : a perspective view of the interior of the Kalibrierringes.

8th : the top view of the Kalbrierring

In 1 is a perspective view of a Rollumformwerkzeug shown, consisting of a single profile roller set 44 with asymmetrical profile rollers 2 is formed. The profile roller set 44 is below a lid 10 arranged and every single profile role according to 2 is on a axle bolt 14 rotatably mounted. The axle bolts 14 are in a housing-fixed recording 5 added.

However, the scope of the invention also relates to axleless mounted in a tool carrier profile rollers.

Thus forms the profile roller set 44 with its inner contour a central recess 16 according to 1 , in which the sheet metal part to be formed 1 is used and with a press stroke, both in the direction of arrow 12 down as well as in the direction of the arrow 13 is then carried out upward, is reshaped.

The embodiment of the 1 and 2 also shows that you can on the profile roller set 44 , with which a finished shape of the longitudinal grooves 30 of the sheet metal part 1 takes place, an additional calibration ring 3 can arrange for additional calibration of the longitudinal grooves produced 30 in the sheet metal part 1 can provide.

The calibration ring 3 consists of a number of spaced apart Kalibrierzähnen 17 , between each of which conical surfaces are arranged, as the basis for calibration 27 be designated. More details will be later on the basis of 7 explained.

Out 2 can be found more details of Rollumformwerkzeuges.

In the interior of the transformable sheet metal part 1 is a rolling pin 4 arranged, whose Outer contour of the later auszuformenden contour of the longitudinal grooves 30 of the sheet metal part 1 equivalent. The rolling pin 4 acts as an opponent and is also in, for example 4 drawn.

The rolling pin 4 is with an upper intake 8th connected, with the drive for recording 8th in conjunction with the rolling pin 4 performed by a press die, not shown, which is capable of the entire structure of rolling mandrel 4 and recording 8th in the direction of the arrow 12 down through the profile roller set 44 by pressing or in turn to raise upward, with the asymmetric profile rollers in the downward and in the upward stroke 2 of the profile roller set 44 for engagement with the sheet metal part to be formed 1 reach.

In the housing-firm admission 5 is still a lower lid 6 attached. This lid 6 takes the profile roll set 44 on and fixes them in cassettes 24 set individual asymmetrical profile rolls 2 so that it is at the required rotational misalignment angle 36 to the sheet metal part 1 comes.

The counterpart 7 holds the sheet metal part 1 against the rolling pin 4 and drives with the whole part 8th . 4 With.

The frame fixed to the frame 9 takes the profile roll set 44 together with the recording 5 and the lid 6 on.

It is still the previously mentioned calibration ring 3 shown, on the upper side of an oil-bearing lubrication 11 has, which circulates on the circumference.

The 2 shows a working condition, which arises from the fact that the recording 8th in conjunction with the attached rolling mandrel 4 in the direction of the arrow 12 was moved down and the sheet metal part 1 already finished by the profile roller set 44 was pressed through and only a calibration in the range of the calibration ring 3 experiences. This condition is in 2 shown.

The profile rollers 2 have during the downstroke in the direction of the arrow 12 and in the direction of the arrow 15 turned.

The rotation takes place about the axis of rotation, which through the respective axle pin 14 given is. After completing the downstroke in the direction of the arrow 12 the backward stroke takes place in the direction of the arrow 13 , The only optional calibration ring 3 will be run twice.

Of course, the invention also includes the kinematic inversion such that profile roller set ( 44 ) with or without the calibration ring ( 3 ) is movably driven and that the sheet metal part 1 with the rolling pin ( 4 ) is stationary.

The 3 schematically shows the top view of the calibration ring 3 with his calibration teeth 17 , which are circular in each case by reset calibration reason 27 are alternated.

It can also be seen how two asymmetric profile rollers 2 in relation to the calibration ring 3 are aligned. From the 3 and 4 is the asymmetry of the profile rolls 2 recognizable after the flank angle Y ( 37 ) the flank 20 from the flank angle X ( 38 ) the flank 20a differs.

Only example is in 3 the deformation area 43 a profile role 2 shown. It extends from the one flank of a longitudinal groove to the same flank 20 the other longitudinal groove.

Out 4 and 5c It turns out that the asymmetric profile roll from a roll collar 18 enlarged diameter, on the left flank 20a connects, which has a first flank angle 38 (Angle X) trains, while on the other side of the rolling collar 18 in the transition to the cylindrically adjoining shoulder band 19 a second flank 20 connecting the second flank angle Y ( 37 ) having.

To the asymmetrical roll collar 18 joins, cylindrical rolling surfaces having, shoulder collar 19 at. These relationships are in 4 shown.

For illustrative simplification reasons, the same groove shape having inner rolling mandrel 4 not shown, the form-fitting to the sheet metal part 1 from the inside rests and supports this.

It is just the calibration ring 3 shown after roll forming for a final calibration in pushing the sheet metal part through the calibration ring 3 according to 2 provides.

It should be noted that the final shape of the longitudinal groove 30 of the sheet metal part 1 already through the single profile roller set 44 with the asymmetric profile rollers 2 is achieved in a single downward and then an upward stroke.

In 4 is recognizable that every profile role 2 with its longitudinal center axis forms a radius beam, which is in the center 45 the profile roller set and thus the sheet metal part 1 united.

Furthermore, it can be seen that the angle Y ( 37 ) the flank 20 is smaller than the angle X ( 38 ) of the flank 20a , making it an asymmetric attack of the asymmetric rolling collar 18 in the interior of the sheet metal part 1 comes.

This will be longitudinal grooves 30 with a groove bottom 31 formed, centric to the center 45 is aligned. It is therefore a rotationally symmetrical sheet metal part.

At the bottom of the groove 31 However, close the side edges 32 . 33 on, which are formed absolutely symmetrical to each other, so that it is after rolling to a rotationally symmetric and also longitudinally symmetrical sheet metal part 1 with symmetrical longitudinal grooves 30 and accordingly also symmetrical Nutengrunden 31 comes.

The side flanks 32 . 33 Thus, they are the same inclined formed, although the engaging in each asymmetric profile rollers 2 an asymmetrical rolled waistband 18 exhibit.

This difference between the asymmetry of the Rollbund 18 the respective asymmetrical profile roll 2 and the symmetrical sheet metal part finally made therefrom 1 is caused by a so-called circular (circumferentially twisted) relative skew angle 36 between the Rollumformwerkzeug and the sheet metal part is given in 4 is registered. The angular misalignment angle is the angle that is between the radius line 35 as a longitudinal symmetry line through a profile roller 2 at the intersection with the center 45 results and a central center line 34 consisting of a radius line 34 , which as a line of symmetry through the longitudinal groove 30 of the sheet metal part 1 is trained.

This is done with an asymmetrical profile roller and an associated rotational offset angle 36 an absolutely symmetrical sheet metal part 1 generated.

By adjusting the relative rotational offset angle 36 of the profile roller set 44 the total existing profile roles 2 in relation to the radius line 34 through the sheet metal part 1 Nevertheless, a symmetrical sheet metal part is achieved.

This results in the advantage of the invention, because by the change in the rotational offset angle 36 (this can be reduced, for example) also an asymmetric sheet metal part 1 can be generated, where the side edges 32 . 33 of the sheet metal part differ in their inclination.

Accordingly, symmetrical or asymmetrical sheet-metal parts with longitudinal grooves uniformly distributed on the circumference can be produced with such a roll-forming tool.

It is still added that the axis line 46 which is the center of rotation of the axle bolt 14 is at right angles to the radius line 35 have to be.

As is clear from the 5a and 5b (Prior art), previously two symmetrical profile rolls were necessary, and according to the invention according to 5c now becomes a single asymmetric profile role 2 used, which according to the prior art symmetrical profile rollers after 5a and 5b united in itself.

What is important is that the asymmetric profile roll 2 an enlarged diameter roll collar 18 has, at the laterally sloping flanks 20 . 20a connect, but with the flanks 20 . 20a differ in their flank angle.

It is essential that the flank adjacent to one side of the roll collar 20a from the shoulder band 19 With a smaller diameter facing away, has a smaller flank angle Y, as compared to the edge 20 , which directly adjoin the shoulder band 19 smaller diameter of the asymmetrical profile roll connects. This flank angle of the flank 20 is denoted by X and is later also by the reference numeral 38 designated.

So it is an asymmetric profile role, in which the enlarged diameter formed roll collar 18 has two different flank angles and this on one side in a shoulder collar 19 passes over, the opposite of the Rollbund 18 has a reduced diameter.

The lateral surface of the shoulder collar 19 is with respect to the line of symmetry of the profile roller (longitudinal symmetry line) cylindrical and parallel to the axis of rotation of the asymmetrical profile roller.

From the above description it follows that the enlarged diameter roll collar 18 penetrates deeper into the sheet metal part as a comparatively smaller diameter in the subsequent shoulder collar 19 , causing an asymmetric deformation of the longitudinal groove of the sheet metal part 1 comes.

It is important that the profile roller set in total by a circular angular displacement angle 36 (please refer 6 ) with respect to a symmetrical radius line 34 offset to the sheet metal part. It is therefore in principle a relative, one-time preset rotational movement of the profile roller set in the circumferential direction with respect to a (thought detained) sheet metal part. For example, if you hold the sheet metal part and the profile roll set by a rotation angle (Drehversatzwinkel 36 ) in relation to the retained sheet metal part at the circumference (circular) twisted and then firmly mounted to the sheet metal part, one comes to the graphic representation 6 , It is therefore a circular rotational offset between the profile roller set and the rolling mandrel to the entire profile roller set of asymmetric profile rollers to a detained sheet metal part 1 is arranged offset.

The more details 4 arise in 6 ,

In 6 the prior art is shown in dotted lines on the right, namely in the form of conventional profile rollers 40 . 41 to 5a , b, which are arranged in the prior art on different levels or had to be summarized in different profile roller sets.

These profile rolls 40 . 41 in the prior art are absolutely symmetrical to the center 45 aligned, and it lacks the rotational offset angle according to the invention 36 to the the asymmetrical profile rollers 2 by a certain angle of z. B. 3 ° with respect to a detained sheet metal part 1 twisted on the circumference are arranged.

For the same parts, the same reference numerals have been used, wherein in the 6 On the left side is evident that from the asymmetrical flanks 20 . 20a of the asymmetrical roll collar 18 symmetrical side edges 32 . 33 of the sheet metal part 1 be generated.

The undeformed lateral surface 47 of the sheet metal part 1 is shown in dotted lines.

The finished molded sheet metal part 1 is shown in solid lines, with the longitudinal groove 30 with the symmetrically adjoining side edges 32 . 33 concerning the groove bottom 31 is shown.

The extrusion molding takes place in the asymmetric profile roll 2 in the indicated direction of the arrow 12 , and it can be seen that this always coincides with the asymmetric roll collar 18 also the cylindrical forming surface having shoulder collar 19 mitläuft and accomplished a corresponding flank training.

The present invention is not an asymmetric profile roll 2 according to 5c limited. It is envisaged in a development that such profile rollers are also present multiple times, ie they form a multiple training a einstoffeinstückige or multi-piece multi-profiled profile role, the in 5c specified profile role 2 then, for example, twice. It can also be designed as a triple part, wherein all parts are material integral with each other.

In another embodiment, it may also be provided, the various parts of each in 5c also shown mechanically interconnect profile roll such. B. by mechanical or material connection means.

In 7 is an embodiment of the shape of a calibration ring 3 already shown in 3 was described and the in 8th is shown in plan view. The explanations regarding the 3 . 7 and 8th as below:
The calibration ring 3 consists of a number of evenly distributed on the circumference arranged Kalibrierzähnen 17 where each calibration tooth 17 from a tooth head 28 consisting of conical in the arrow directions 12 . 13 Beveled upward and also in a subsequent also in the direction of the arrow 12 . 13 tapered tooth root 29 passes.

The tooth head 28 consists of a conically upwardly extending front edge 23 , which is wedge-shaped and which has a certain angle in the form of an insertion bevel for insertion into the longitudinal groove 30 of the sheet metal part 1 having, wherein the double conical front edge 23 two lateral sides with double conical sides 22 connect.

In the same way, but only in an extended version, the tooth root 29 a double conical front edge 23a on, in turn, the double-conical side edges 22a connect.

Total form so tooth head 28 . 29 each insertion bevels for the penetration into the longitudinal groove 30 of the sheet metal part 1 so as to give a final calibration of the side edges 32 . 33 in connection with the groove bottom 31 of the sheet metal part 1 to provide.

To the calibration tooth 27 close set back on a radius jet, in each case evenly distributed on the circumference arranged Kalibriergrunde 27 with each calibration reason 27 again an upper end flank 26 has, to which a lower end edge 26a followed.

Also these two front edges 26 . 26a are in the arrow directions 12 . 13 inclined formed to also form an insertion bevel for penetration into the longitudinal groove 30 of the sheet metal part 1 ,

In 8th is the top view of the calibration ring 3 shown where the alternating array of calibration teeth 17 in conjunction with the subsequent calibration reason 27 is shown.

On the outer circumference of the calibration ring 3 is a circumferential lubrication groove 11 formed, which is recessed in the cover-shaped material of the Kalibrierringes is introduced and via which a lubricant is input via receiving grooves to the parts 17 . 27 to lubricate.

By the arrangement of the lubrication groove 11 in the area of an approximately plate-shaped calibration ring 3 There is the advantage that you can lubricate during the forming process, as for example in 2 is shown.

LIST OF REFERENCE NUMBERS

1

sheet metal part

2

Profile roll asymmetric

3

calibrating

4

roll Dorn

5

admission

6

Lid down

7

backstop

8th

Recording above

9

frame

10

Top lid

11

lubrication groove

12

arrow

13

arrow

14

axle

15

direction of rotation

16

recess

17

Kalibrierzahn

18

roll Bund

19

shoulder Bund

20

flank 20a (from 3 )

21

22

Side flank ( 28 ) 22a

23

Front edge ( 28 ) 23a

24

25

26

Front edge ( 27 ) 26a

27

Kalibriergrund

28

addendum

29

tooth root

30

Longitudinal groove (from 1 )

31

groove base

32

Side flank (from 1 )

33

Side flank (from 1 )

34

Radius line (from 1 )

35

Radius line (from 2 )

36

Rotary offset angle

37

Angle Y (from 20 )

38

Angle X (from 20a )

39

Wall (from 1 )

40

conventional profile roller

41

conventional profile roller

42

annular flange

43

deformation zone

44

Profile roller set

45

center

46

axle line

47

Lateral surface (from 1 )

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• WO 2009/124534 A2 [0002]

Claims (10)

Method for producing an internally and externally toothed cup-shaped sheet metal part ( 1 ), in which the untoothed cup-shaped sheet metal part ( 1 ) on one, with one of the internal teeth of the sheet metal part to be produced ( 1 ) corresponding external toothing, trained rolling mandrel ( 4 ) and then the outer profile on the cup-shaped sheet metal part ( 1 ) is rolled by the cup-shaped sheet metal part ( 1 ) together with the rolling mandrel ( 4 ) by a parallel to the central axis ( 45 ) on the sheet metal part ( 1 ) under the exercise of a radial pressure rolling profile roll set ( 44 ), whereby the material of the sheet metal part ( 1 ) in the tooth grooves of the rolling mandrel ( 4 ) is pressed, characterized in that in a single step in the course of a single press stroke (up and down movement of the rolling mandrel 4 ) a finished formation of the longitudinal grooves in the sheet metal part ( 1 ) he follows. A method according to claim 1, characterized in that the final formation of the longitudinal grooves in the sheet metal part ( 1 ) additionally connects a calibration process. A method according to claim 1 or 2, characterized in that the calibration process during the downward and upward strokes of the rolling mandrel ( 4 ) takes place. Device for producing an internally and externally toothed cup-shaped sheet metal part ( 1 ), in which the undeformed sheet metal part ( 1 ) on one with one of the internal teeth of the sheet metal part to be produced ( 1 ) corresponding external teeth trained rolling mandrel ( 4 ) with a longitudinally movably driven pressing tool by a fixedly arranged profile roller set ( 44 ), consisting of a plurality of uniformly arranged on the circumference profile rollers ( 2 ) is movable through, characterized in that the profile rollers ( 2 ) form an asymmetrical rolling circumference which rolls out the longitudinal groove in the sheet metal part, and in that a circular (over the circumference twisted) relative rotational offset angle ( 36 ) between the profile roll set ( 44 ) Roll forming tool and the sheet metal part ( 1 ) is available. Apparatus according to claim 4, characterized in that the asymmetrical profile roller ( 2 ) from a roll collar ( 18 ) of enlarged diameter, on which on one side a flank ( 20a ), which has a first flank angle 38 (Angle X) is formed, while on the other side of the roll bundle ( 18 ) in the transition to a cylindrically adjoining shoulder collar ( 19 ) a second flank ( 20 ), one from the first flank angle ( 38 ) deviating, second flank angle Y ( 37 ) having. Device according to claim 5, characterized in that the angle Y ( 37 ) the flank ( 20 ) is smaller than the angle X ( 38 ) the flank ( 20a ), so that it leads to an asymmetric attack of the asymmetric roll bundle ( 18 ) in the interior of the sheet metal part ( 1 ) comes. Device according to one of claims 4 to 6, characterized in that the side edges ( 32 . 33 ) of the sheet metal part ( 1 ) are formed inclined and that in each engaging asymmetric profile rollers ( 2 ) an asymmetric roll collar ( 18 ) exhibit. Device according to one of claims 1 to 7, characterized in that the rotational offset angle ( 36 ) is the angle between the radius line ( 35 ) as longitudinal symmetry line through a profile roller ( 2 ) at the intersection with the center ( 45 ) of the roll forming tool and from a radius line ( 34 ), which the symmetry line through the longitudinal groove 30 of the sheet metal part 1 is, results Device according to one of claims 4 to 8, characterized in that with the device, the method according to one or more of claims 1 to 3 is exercised. Roll formed sheet metal part ( 1 ) characterized in that it is designed as a symmetrical sheet metal part ( 1 ) with a profile roller set ( 44 ) made of asymmetric profile rolls ( 2 ) and a rolling pin ( 4 ), wherein a relative rotational offset angle ( 36 ) between the profile roll set ( 44 ) and the rolling mandrel ( 4 ) given is.

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