DE10219441C1 - Machine tool for the production of inner/outer roller bearing and gear rings ready for grinding, from tubular or solid workpieces, uses a combination of lathe turning and profile roller shaping in series and/or in parallel - Google Patents

Abstract

For the production of inner and/or outer roller bearing and gear rings, from tubular or solid workpieces, the metalworking is through turning by a lathe and shaping by radial-axial profile tube rollers and/or roller plunge-cutting, combined with each other in series and/or in parallel. The machine tool to produce the bearings rings, ready for grinding, has an outer (2) and an inner (3) profile roller tool, together with a lathe turning mechanism. A counter pressure tool (5) with an axial sliding movement is at the inner profile roller tool, to limit the material flow, forming a laying surface for the tube workpiece (1) extending beyond the outer diameter of the inner profile roller tool. The material flow can be controlled in an axial and/or radial direction by a hydraulic system (7-9) acting on the vertical (10) and horizontal (11) compound slide rests.

Description

The invention relates to methods and arrangement for combined forming and cutting the production of inner and / or outer profiled rings from tubular or solid material Radial-axial profile tube rollers in combination with turning. The procedure and the arrangement are used to manufacture u. a. cylindrical starting rings, rolling bearing rings and Ge drive rings or the like

The production of profiled rings, in particular roller bearing rings, from preferably tubular material al, is done either by machining or in a combination of machining and reshaping Bear processing.

With purely machining, which is very material-intensive, you can richly smaller 100 mm outer diameter highly productive multi-spindle automatic lathes for Use, whereby by single-ring or multi-ring machining, preferably two-ring Machining, one or more, preferably two, ready-to-grind profiled rings at the same time can be manufactured from one machine to another without reclamping.

In certain combined processes consisting of at least two work steps on ver machines of various types will first become a so-called blank, i.e. a cylindrical one Starting ring, starting from pipe material or bar steel, also cutting or through Combination of cutting and forming processing, which is then produced by Axial or tangential profile ring rollers is profiled ready for grinding. This combined procedure Ren for the production of profiled rings are compared to the pure machining on Mehr Spindle automatic lathes are more economical in terms of material and in terms of their properties stiger, but require at least one more clamping of the blank (initial ring ges) for profiling the ring an increased amount of work as a result of the thus required processing on at least two different machines until one is available ready to grind ring.

An example of these combined methods in at least two work steps is in DE 198 49 182 A1 with the objective of influencing the process-related axial or tangential work material flow described. However, the material influence involves at least two rolling steps (Operations) ahead, which is an already described major disadvantage of this manufacturing facility is.

The economic application of the above-mentioned processes lies in especially in the dimension range larger than 100 mm outside diameter and mainly comprises Outer and inner rings (rolling bearing and gear rings) with a symmetrical cross-sectional shape. There are also proposed solutions (DE 197 43 055 A1, DE 199 20 163 A1) for Ferti  of rings with asymmetrical cross-sectional shape through tangential profile ring rollers, for which, however, has not yet been used in practice.

Other manufacturing processes for the production of profiled rings are based on a combination first forming processing by axial profile tube rolling and / or roller grooving and then machining by turning starting from pipe material (DD 225 358 A1) or initially machining pre-processing of pipe material (DD 292 162 A5) or Bar steel (DD 292 161 A5) with subsequent forming by axial profile tube rolling and / or grooving as well as machining of a ring in succession and / or in parallel on a multi-spindle automatic lathe with integrated rolling device, only affect rings with a symmetrical or asymmetrical shape Cross-sectional shape, such as B. Inner rings for radial deep groove ball bearings or tapered roller bearings.

DE 195 26 900 A1 describes machining processes such as turning and forming processes such as Axial profile tube rolling and / or grooving combined so that at least one ring simultaneously reshaping inside or outside and / or machined ready for grinding can, in addition to the above-described production of externally profiled rings, such as Example inner bearing rings, as well as the production of internally profiled rings, such as Example of rolling bearing outer rings, with the aforementioned process combination.

For the last-mentioned manufacturing process, Ver driving combination, a machine is used to shape the profiling of the exterior and inner contour of rings during machining of all other shapes and surfaces chenelemente of the ring, including the separation of the ring from the tube as the last Ar step in one operation without reclamping.

The unprocessed pipe is advantageous by turning it outside and / or turning it inside preformed to shape by axial profile tube rolling and / or grooving, whereby at the same time, if necessary, required minimum chip reductions or existing decarburization the raw material used is taken into account.

The economic application of the manufacturing process for combined forming and machining by axial profile tube rolling / grooving turning to Fer profiled rings are in the size range of approx. 40. .160 mm outer diameter and includes internally and / or externally profiled rings (rolling bearing and gear rings) with both symmetrical as well as asymmetrical cross-sectional shape. There is also the possibility  the production of initial rings for further machining or forming, z. B. by axial or tangential profile ring rolling. This is particularly advantageous if the initial rings for the subsequent rolling must be pre-profiled, as is the case with the axial or tangential profile ring rolling of complicated ring geometries is essential.

Common to those in DD 225 358 A1, DD 292 162 A5, DD 292 161 A5 and DE 195 26 900 A1 illustrated manufacturing processes that in axial profile tube rolling and / or grooving an unimpeded axial material flow occurs. The result is that the tube or ring during the Rolling process according to the volume of material displaced by the tool profile (up to 100%) longer or wider. This effect is in the sense of a high material Utilization and economy in the ring production aimed. When editing Rings with large and deep rectangular profiles (groove-like profiles), such as B. with synchronous Gear rings or gearshift sleeves lead to problems in achieving the gefor other accuracies (symmetries).

The object of the invention is to the method and arrangement of the type mentioned admit, with a higher accuracy in the production of rings with large and deep Rectangular profiles (groove-like profiles), such as B. with synchronous gear rings or shift sleeve fen is reached.

According to the invention the object is in connection with that in the preamble of claim 1 Features mentioned solved that a counterforce during the rolling of the profile is generated with respect to the flow direction of the pipe material, with which the material flow in the axial and / or radial direction can be controlled so that the flowing material in the formation of the Profiles is included.

By generating a counterforce or a counter pressure, this is unhindered axial material flow counteracted with a defined force to be applied. So that will the possibility of controlling the material flow in either axial and / or radial (for Pipe outer diameter towards) created direction, with which the z. B. in the manufacture of Problems with synchronous gear rings and shift sleeves occurred with regard to achieving the required accuracies, especially with regard to the symmetry of groove-like profiles, be solved.  

Advantageous variants of the method result from the dependent subclaims mentioned features.

The task is further through an arrangement in conjunction with the in the preamble of Features mentioned claim 6 solved in that the inner profile rolling tool a Material flow limiting axially displaceable counter pressure tool, which has a bearing surface for the outer diameter of the inner profile rolling tool forms the tube to be formed, with which the material flow in the axial and / or radial direction is controllable.

The axial displacement can also be used to control the axial flow of material of the external profile rolling tools through a hydraulic and / or mechanical system promoted or restricted.

The use of such a counterpressure device (including a rolling mandrel) leads to a decisive one Extension of the known process combination of axial profile tube rolls (and / or rollin pricking) -turning to a completely new process combination "radial-axial- Profile tube rolling "and / or roll grooving. Another advantage of this method Combination with controllable axial material flow is that from a tube "smaller" Au outer diameter rings with (slightly) larger outer diameter can be produced, what from the now controllable radial material flow (towards the pipe outside diameter) results. Manufacturing is possible through the use of radial-axial profile tube rolling capabilities for the production of a much larger range of parts than with the previously known Procedures or solutions.

The invention is explained in more detail below on the basis of exemplary embodiments. In the drawings show:

Fig. 1 (spindle position I) outside overturning with overturning tool and inside turning out with unscrewing tool of tube 1

Fig. 2 (spindle position II) (outer) radial-axial profile tube rolling / grooving with profile rolling tool 2 and counter pressure tool (incl. Rolling mandrel) 5

Fig. 3 (spindle position III) facing (1st ring side) with facing tool, internal turning (turning) with turning tool and CNC contour turning (turning) with turning tool

Fig. 4 (spindle position IV) parting off with parting tool of the synchronous gear ring 4 and facing (2nd ring side) with facing tool

Fig. 5a (outer) radial-axial tube profile rollers / Walzeinstechen with outer profile rolling tool 2 and counter-pressure tool (incl. Roll mandrel) 5 of the tube 1 and so profiled synchronously gear ring 4

Fig. 5b with a corresponding tool configuration shown in Fig. 5a for controlling the material flow in the axial or radial direction from an initial tube smaller diameter sers profiled synchronous gear ring with rolled profile

Fig. 6a on the output tube 1 rolled double profile corresponding to the outer contour of two synchronous gear rings

Fig. 6b on the output tube 1 rolled double profile corresponding to the outer contour of two synchronous gear rings 4 in rolls with a so-called front ring

Fig. 7a radial-axial tube profile rollers / Walzeinstechen with outer profile rolling tool 2 and NEN-profile rolling tool (incl. Roll mandrel) 3 of the starting tube 1 and so profiled synchronous gear ring 6

Fig. 7b with the tool configuration shown in Fig. 7a for controlling the material flow in the axial or radial direction from a starting tube smaller diameter sers profiled synchronous gear ring (with outer and inner profile) larger diameter sers

Figure 8 is schematic illustration of a rolling apparatus for selectively controlling the axial and radial material flow with hydraulic and / or mechanical support.

In Figs. 1 to 4 the combination of the invention is cutting and forming Ver drive through radial-axial section tube roll rotating with counter-pressure device for material flow control on the basis of the associated production run (single ring machining) accordingly the spindle positions I to IV of a four-spindle automatic lathes with Integrated Walzvor direction shown on the example of a synchronous gear ring starting from a tube in one setting.

In spindle position I, an external overturning and internal unscrewing of the output tube 1 used is first carried out. In spindle position II, the (outer) radial-axial profile tube rolling / grooving with profile rolling tool 2 takes place according to the outer contour of a synchronous gear ring with counter pressure tool (including rolling mandrel) 5 (see also FIG. 5a) for controlling the material flow, which means that the material under consideration Application of the axial material flow is partially obstructed and as a result is partially directed in the radial direction. Since it is possible to manufacture a synchronous gear ring 4 (slightly) larger in diameter from a tube 1 of smaller diameter (see FIG. 5b). The permitted axial material flow must be taken into account when feeding the pipe in order to ensure the required workpiece width.

In the spindle positions III and IV, the final machining of the remaining form or surface elements of the ring takes place with the separation of the completely ready-to-grind profiled synchronous gear ring 4 from the tube 1 as the last working step.

Thereby, face turning of the 1st ring side, inside turning and CNC contour turning of the outside contour are carried out in spindle position III. The latter two working stages are only re-turning operations. When turning out again on the inside, the elimination of the "rolling marks" caused by the radial-axial profile tube rolling is carried out in the tube or ring inside diameter. CNC contour turning is a pure "safety measure" and only serves to ensure 100% certainty that the accuracy requirements will be met. As a rule, CNC contour turning is not necessary, since the required accuracy of the outer contour can be achieved with radial-axial profile tube rolling, guaranteed by using the counterpressure device. In spindle position IV, the fully synchronized gear ring 4, which is profiled ready for grinding, is tapped off from tube 1 and the facing of the second ring side.

The outside overturning or inside turning out shown in spindle position I is in use of raw material with the appropriate surface quality and that of the work appropriate outer or inner diameter not necessary in every case, whereby through radial-axial profile tube rolling / grooving the dimensions of the outside or inside knife can be changed within a small tolerance range.

Should with the manufacturing process described in FIGS. 1 to 4 z. B. a shift sleeve with internal teeth can be manufactured, the outer contour can be rolled completely ready for grinding, while the teeth in the inner diameter is machined on a downstream device in a separate operation, advantageously a concatenation of the devices is realized.

The manufacturing process shown in FIGS . 1 to 4 is also possible when realizing a two-ring or multi-ring machining, that is, in this case the radial-axial profile tube rolling is carried out with profile rolling tools according to the outer contour of two or more synchronous gear rings. Rolling with a so-called “front ring” ( FIG. 6) is advantageous for this. This means that first - a ring profile remaining on the tube - is rolled by (radial) axial profile tube rolls, behind which the rolling z. B. connects two further ring profiles, so that there are three rolled ring profiles on the tube. The third ring profile remains on the tube while the two upstream ring profiles are machined and then separated from the tube and forms the "pre-ring" in the sequence of repetitive manufacturing processes. This considerably stabilizes the rolling process, since rolling at the start of the pipe is avoided and tool intervention is not carried out directly at the start of the pipe, but offset at least one ring width from the start of the pipe. This enables the accuracy requirements to be easily secured even with multi-ring machining. By rolling with "Vorring" a mutual influencing of the individual ring profiles due to the axial material flow is avoided. This variant can be implemented both with and without the use of a counter pressure device.

The manufacturing process shown in the exemplary embodiment for preferably pipe material is shown in FIG modified way also when using steel bars as the starting material, in particular for smaller ring dimensions, possible.

If a workpiece such. B. the synchronous gear ring shown in FIGS . 1 to 4 are manufactured, which additionally has a circumferential inner profile 6 , there is the possibility of appropriate process design, the inner and outer contour of the ring simultaneously either reshaping by radial-axial profile tube rolls and / or roll grooving or one of the two contours to produce purely by turning in succession and / or in parallel. Likewise, all work steps can be carried out in one work step on a machine, including the separation of the completely finished ring from the pipe, which is ready for grinding, as the last work step. Fig. 7 shows the radial-axial profile tube rolling at the same time the outer and inner contour of such a workpiece.

For the mechanical implementation of the manufacturing sequence shown in FIGS . 1 to 4, there are two advantageous arrangement variants.

On the one hand, the object is achieved according to the invention with an arrangement as in DE 195 26 900 A1 described solved. Here is on a known multi-spindle automatic lathe in egg ner spindle position a rolling device is provided.

The rolling device has diametrically arranged, axially displaceably mounted, optionally driven or non-driven external profile rolling tools, which are arranged on a common base plate to avoid radial forces on the spindle bearing. The axial displaceability of the external profile rolling tools can be promoted or restricted depending on the application by a hydraulic and / or mechanical system, so that a targeted control of the axial material flow is possible. The external profile rolling tools can be adjusted with a radial feed force that causes penetration into the pipe. In spindle position II, a cross slide 10 is installed on a further cross slide 11 for receiving either an optionally driven or non-driven inner profile rolling tool, in order to realize its penetration into the tube with a radial feed force. In connection with this or separately, the counter-pressure device (including the rolling mandrel) can be accommodated by the cross slide 10 . B. is applied via an additional hydraulic and / or mechanical system to be integrated defined. This additional system is shown in Fig. 8 as a hydraulic system. Depending on the size of the pressure of the hydraulic medium 9 in the hydraulic cylinder 8 , the axial material flow to the pipe start can be reduced or "reversed" to the clamping point via hydraulic pistons 7 and counter-pressure tool 5 . At the same time, this enables a radial flow of material towards the outside diameter. The correct selection of the hydraulic pressure that changes during the rolling process ensures the necessary accuracies with regard to dimensional accuracy, in particular symmetry, of the groove-like profiles.

Advantageous for the mechanical implementation of a radial-axial profile tube roll designated combination of methods is a specially tailored arrangement Basis of a (multi-spindle) automatic lathe with integrated rolling device. A simple lion solution is a single-spindle machine, the structure of which is based on a modular principle As soon as an optional upgrade and disassembly of the machine with spindle positions, roller devices and rotary units depending on the degree of complexity of the to be manufactured Ring is guaranteed.

It is essential in the arrangement according to the invention that the inside and / or outside are simultaneously be shaped and / or machined profile of a ring in a clamping can, the separation of the completely grinded ring from the tube in each Case represents the last stage of work.

It is also possible to implement the mechanical implementation of the combination of processes Ra dial-Axial-Profilrohrwalzenwalzen on several interlinked modified pro filwalzmaschinen and lathes, but at least with a profile rolling machine and a lathe. The profile rolling machine used for this purpose is designed so that it corresponds to the representation of the rolling device shown in FIG. 8.

The essential features of this arrangement are that of a profile rolling machine one (or more) machining devices or lathes are assigned, immediately after the shaping by radial-axial profile tube rolls Forming and / or cutting the pipe and cutting the finished machining of the Ring only takes place in the "separated" state from the pipe. The separated -  pre-profiled - ring from the downstream machining equipment or Lathes taken over without intermediate storage.

While the first variant especially for "smaller" ring dimensions (approx. 40 ... 100 mm Outside diameter) is suitable, the second variant comes in particular for "larger" Ring dimensions (approx. 100 ... 160 mm) into consideration. In principle, however, both are arrangement variants for a size range of approx. 40.. .160 mm outer diameter both tech nisch as well as economically suitable. An extension to outer diameter ranges larger 160 mm is possible.  

LIST OF REFERENCE NUMBERS

1

pipe

2

Exterior roll-forming tool

3

Inside profile rolling tool

4

Synchronous gear ring (without inner profile)

5

Counter pressure tool (including rolling mandrel)

6

Synchronous gear ring with inner profile

7

hydraulic pistons

8th

hydraulic cylinders

9

hydraulic medium

10

Cross slide (vertically movable)

11

Cross slide (horizontally movable)

Claims (10)

1. Process for the production of internally and / or externally profiled rings, in particular of rolling bearing rings and gear rings in a completely ready-to-grind state from pipe or solid material, in the cutting processes such as turning and forming processes such as Ra dial-axial profile pipe rolls and / or roll grooving in Sequence and / or in parallel with each other, characterized in that a counterforce is generated with respect to the flow direction of the pipe material during the rolling of the profile, with which the material flow in the axial and / or radial direction can be controlled so that the flowing material into the formation of the profile is included. 2. The method according to claim 1, characterized in that the control of the material flow takes place via a counter-pressure tool ( 5 ) which counteracts an unimpeded axial material flow with defined force to be applied and consequently generates the material flow optionally in the axial and / or radial direction. 3. The method according to claim 1 or 2, characterized in that the control of the axial Material flow through an additional promotion or limitation of the axial Ver sliding of the external profile rolling tools by hydraulic and / or mechanical Means is realized. 4. The method according to any one of claims 1 to 3, characterized in that for realizing Two-ring or multi-ring machining at the same time according to the outer contour two or more rings are rolled with a front ring, first by one on the tube remaining ring profile by (radial) axial profile tube rolling and / or grooving is rolled, which is followed by the rolling of further ring profiles, so that several ge rolled ring profiles are created on the pipe, with the last ring profile being during the upstream ring profiles machined and then separated from the tube remain on the pipe and the repetitive manufacturing process Vorring forms. 5. The method according to any one of claims 1 to 4, characterized in that the interior and / or external profiling of the ring is carried out in one setting.   6. Arrangement for the production of internally and / or externally profiled rings, in particular of rolling bearing rings and gear rings in a completely ready-to-grind condition from tubular or solid material, comprising a rolling device with an outer ( 2 ) and an inner profile rolling tool ( 3 ) and, if appropriate Further devices for turning, characterized in that the inner profile rolling tool ( 3 ) has an axially displaceable counterpressure tool ( 5 ) which limits the material flow and which forms a bearing surface for the tube ( 1 ) which projects beyond the outer diameter of the inner profile rolling tool, with which the material flow in the axial direction and / or radial direction is controllable. 7. Arrangement according to claim 6, characterized in that in a multi-spindle automatic lathe, the rolling device is provided with an outer ( 2 ) and an inner profile rolling tool ( 3 ) in a spindle position. 8. Arrangement according to claim 6, characterized in that in a combination of we at least one profile rolling machine and one lathe of the profile rolling machine several machining devices or lathes are assigned to the Ring immediately after shaping by radial-axial profile tube rolls Separate from the pipe in a shaping and / or machining process and finish machining the Ringes only in the state already separated from the pipe, with delivery of the separated and pre-profiled ring to the downstream machining equipment or Lathes without intermediate storage. 9. Arrangement according to one of claims 6 to 8, characterized in that the profile rolling tools ( 2 ; 3 ) by means of respectively assigned hydraulic pistons ( 7 ) and hydraulic lik cylinder ( 8 ) are axially displaceable. 10. The arrangement according to claim 9, characterized in that the inner profile rolling tool ( 3 ) with the counter-pressure tool ( 5 ) by means of a pressurizable piston-cylinder arrangement with the cross slide ( 10 ) is connected.