EP2263812A1 - Method for producing stamped parts, in particular synchronous rings, coupling bodies or coupling discs - Google Patents

Abstract

The method involves clamping the belt material (1) between the blank holders of a fine cutting tool in one process step. The teeth (10) are stamped in a further process step. A stream pre-stamping of teeth is carried out in the area in the former process step. The procedural step of the fine cutting takes place in connection with an extrusion in the belt material. An independent claim is also included for a device for the production of stamped units, particularly synchronous rings, clutch bodies or clutch disks.

Description

The invention relates to a method for producing stamped parts, in particular synchronizer rings, coupling bodies or clutch plates, in two process steps without interrupting the process in the same press (Appendix).

According to JP-A-06234027 (closest prior art) punched parts, in particular of synchronizer rings, coupling bodies or clutch plates, produced in that in a device with only a tool in a first process step, a workpiece is punched or finely punched and in a second process step by punching on the workpiece resulting ridges or functional surfaces are brought to their final dimension or functional surface by machining.

Process steps produced: stamping, deburring, machining and visual inspection. During punching, the workpiece is punched out of the raw material. In this process step, burrs occur on the outer and inner contours. When deburring these burrs are e.g. removed by vibratory grinding, belt grinding or brushing. In machining, the workpiece is brought to a predetermined flatness (smoothness) in the functional surfaces, which can not be reached by punching or whose contour can not be achieved by punching. For the machining, the stamped part is taken from the press, partially stored and fed to a cutting machine.

The last step is the visual inspection. During visual inspection, the workpiece is checked for damage.

The invention has the task of reducing the manufacturing costs and the production time.

The object is achieved by a method according to claim 1. In this case, the method comprises only two process steps. In a first process step, an extrusion process, the so-called Fließvorprägen is performed, which introduces a pre-orientation and partial work hardening in the supplied raw material.

The molded-in precise shape is introduced depending on the contour of the stamped part to be punched and, in the subsequent fineblanking process, enables a combined fine-shearing and extrusion-molding in one tool stage. The pre-orientation of the raw material carried out first enables extrusion in the combined cutting and extruding stage by creating a void volume within the mold which can be filled by the proportionate extrusion process in the fineblanking stage.

The solution according to the invention has the advantage that the workpiece is produced in only one tool and from strip material / from the coil or from blanks which are supplied individually. An intermediate processing by grinding or machining operations omitted. Another advantage is that intermediate storage and transport are also eliminated.

In one embodiment, it is proposed that during a working step in the fineblanking stage, a first component of raw material is preformed by flow predrilling and at the same time fineblanking and extrusion are carried out in the fineblanking stage in a second workpiece.

In a further embodiment of the invention it is proposed that after completion of an operation, the first component is transported automatically by means of a handling device from the flow preforming stage for fineblanking stage. The second component is simultaneously removed from the device and the flow preforming stage is loaded with a new raw material.

An essential feature of the present invention is that initially in the strip material flow extrusion takes place, in this case flow preforms are embossed according to the number of teeth of the subsequently configured synchronizer ring without punching or injuring the strip material.

It is thus cup-shaped depressions which are embossed in the strip material without tearing or opening the strip material at this point.

Important in the selection of the embossing stamp is that the number of embossing corresponds to the number of teeth of the later synchronizer ring.

However, the choice of embossing form can be varied within wide limits.

Although it is preferred if the embossed cup in its shape corresponds approximately to the later tooth of the synchronizer ring, but the invention is not limited thereto.

In another embodiment, it may be provided that the diameter of the root circle of the forms deviates from the diameter of the root circle of the later teeth, in particular is smaller.

In another embodiment, it may be provided that the diameter of the top circle of the forms is also smaller than the later head diameter of the teeth of the synchronizer ring.

The depth of the cup-shaped Fließvorprägung or embossing depends on the later tooth contour.

In a preferred embodiment, the bottom of the cup-shaped Fließvorprägung is flat, d. H. formed horizontally when the tape material is aligned horizontally.

In this case, it is not necessary for the solution that the side walls, which define the cup shape, are directed exactly vertically. You can also open conically upwards. They should be as symmetrical as possible.

Likewise, it may be provided in another embodiment that the bottom is curved in order to achieve a steady transition into the side walls of the cup-shaped Fließvorprägung.

After carrying out the flow pre-embossing is then punched through with another tool, this tool is designed as a fine cutting tool.

According to the invention, therefore, no embossing of the punching burrs takes place, but the teeth are formed with a fine blanking process and simultaneously subjected to extrusion. In order to make this possible one needs a free volume which is obtained by the so-called flow advancing.

It is important that the stage 1, in which the Fließvorprägung takes place, is arranged in the same tool as comparatively the stage 2, with the means of a cutting tool, the outer and inner contour of the synchronizer ring is finally cut out of the strip material.

It is important that the cutting tool now cuts into the cup-shaped depressions of the flow preform, wherein the arranged at the bottom of the cup-shaped recess strip material can be referred to as flow material, which is hineinverdrängt in the subsequent fine cutting in the conical recess of the cutting tool and there a flow-pressing operation is subjected.

Thus, in addition to the fine cutting process, a flow process is triggered on the flow material, wherein this flow material is arranged in the region of the later tooth of the synchronizer ring.

Thus, as it were, each tooth of the synchronizer ring is subjected to a flow process which is thus displaced into a conical receiving form and subjected to a cold flow process.

This has the significant advantage that the tooth structure is work-hardened in the area of this synchronizer ring by the cold-flow forming process becomes. This gives the synchronizer ring, coupling body or clutch disc a significantly longer service life, higher wear resistance and is burr-free, moreover, without the need for further processing.

In another embodiment of the invention, it may then be additionally provided that the synchronizer ring, coupling body or clutch disc is hardened. However, this is for the illustrated invention of no crucial importance.

The subject of the present invention results not only from the subject matter of the individual claims, but also from the combination of the individual claims with each other.

All information and features disclosed in the documents, including the abstract, in particular the spatial design shown in the drawings, are claimed to be essential to the invention insofar as they are novel individually or in combination with respect to the prior art.

In the following the invention will be explained in more detail with reference to drawings showing only one embodiment. Here are from the drawings and their description further features essential to the invention and advantages of the invention.

Figur 1:

die Draufsicht auf ein Bandmaterial bei der Verarbeitung des Bandmaterials in insgesamt drei Stufen

Figur 1a:

ein Schnitt gemäß der Linie la in Stufe 1 nach Figur 1

Figur 2:

Schnitt gemäß der Linie II-II in Figur 3 durch einen freigestanzten Synchronring, Kupplungskörper oder Kupplungsscheibe

Figur 3:

die Draufsicht auf den Synchronring, Kupplungskörper oder Kupplungsscheibe

Figur 4:

schematisiert der Fließ-Pressvorgang beim Bewegen des Ober- und Unteniverkzeuges gegeneinander

Figur 5:

eine weitere Ausführungsform im Vergleich zu Figur 1 bis 4, bei der zusätzlich an die Zahngeometrie noch eine Dachform angeprägt wird, wobei

Figur 5a:

die Bandform nach der Fließvorprägung zeigt

Figur 5b:

das Anprägen der Dachform

Figur 5c:

das Ausschneiden des Synchronringes, Kupplungskörper oder Kupplungsscheibe mit gleichzeitigem Prägen der Dachform

Figur 5d:

ein weiteres Fließpressen bei dem die Endkontur der Zahnform kalibriert wird.

Figur 6:

eine perspektivische Darstellung der in den Figuren 5a bis 5d hergestellten Zähne mit Dachform

Show it:

FIG. 1:

the top view of a strip material in the processing of the strip material in a total of three stages

FIG. 1a

a section according to the line la in step 1 after FIG. 1

FIG. 2:

Section according to the line II-II in FIG. 3 by a punched synchronizer ring, coupling body or clutch disc

FIG. 3:

the top view of the synchronizer ring, coupling body or clutch disc

FIG. 4:

schematizes the flow-pressing process when moving the top and bottom tool against each other

FIG. 5:

another embodiment compared to Figure 1 to 4 , in which in addition to the tooth geometry still a roof shape is impressed, wherein

FIG. 5a

shows the band shape after the Fließvorprägung

FIG. 5b:

the embossing of the roof shape

FIG. 5c:

the cutting out of the synchronizer ring, coupling body or clutch disc with simultaneous embossing of the roof shape

FIG. 5d:

another extrusion in which the final contour of the tooth shape is calibrated.

FIG. 6:

a perspective view of the in the FIGS. 5a to 5d manufactured teeth with roof shape

In the figures, exemplary embodiments and different views are shown. In Fig. 1 the top view is shown on a stripe image. The strip material 1 is provided in a first stage with a flow preform 3, which results in fine cutting in step 2 a custom-made component 2.

The FIG. 1 This shows a stage 1, in which the Fließvorprägung is made in a strip material 1 of a metal strip. In this case, cup-shaped flow preforms 3 are embossed into the strip material, as shown schematically in FIG FIG. 1 a is shown. The tip circle 9, which defines the outer diameter of the cup-shaped flow preforms, corresponds to FIG later tip circle 9 of the teeth 10 on the synchronizer ring, coupling body or clutch disc (component 2).

The root circle of the cup-shaped flow preforms may deviate from the root circle of the later teeth 10. In particular, it can be smaller.

It is also important that the width 11 of the cup-shaped flow preforms corresponds approximately to the width of the later teeth 10 in the foot region.

Stage 2 now shows that the exact geometry of the tooth is cut out with a cutting tool and in step 3 is in FIG. 1 illustrated that after cutting out of the synchronizer ring, coupling body or clutch disc, which is referred to as component 2, a punched hole 16 remains in the strip material 1.

It is important that during flow advancement of the cup-shaped flow preforms 3 a flow material 18 remains in the area below the flow preform 3, which is then pressed into the gap between the punch 6 and the lifter 7 in a flow-pressing operation and is deformed there.

This is based on the FIGS. 2 to 4 described in more detail.

The strip material 1 is in this case in the intermediate space between an upper tool and a hold-down device 5a associated therewith, as well as a lower tool and a hold-down 5b associated therewith.

The contact pressure between the two hold-downs 5a, 5b is so great that a deformation of the component 2 during fine blanking is avoided in any case.

At this stage, a punch 6 now moves from above in the direction of arrow 14 down and simultaneously moves from below a lifter 7 in the direction of arrow 15 upwards, so that the two tools 6, 7 meet in the region of a cavity 4 in the holddown 5b of the lower tool is arranged.

It is important that this cavity is tapered with its side surfaces 12, so that the cup-shaped flow preform 3 is pressed with its flow material 18 in this conical cavity 4 and is flow formed there.

Here it comes to a cold flow of the deformed material and to a structural transformation.

This is schematized again in FIG. 4 shown in an intermediate stage, where it can be seen that the tooth 10 of the component 2 is pressed into the conical cavity 4 in the direction of arrow 14 and thereby comes to flow. The bottom 13 of the cavity is in this case preferably flat.

Likewise, in another embodiment, the bottom 13 can also be slightly cambered, corresponding to the cambered bottom of the cup-shaped flow preform 3 in FIG FIG. 1 a.

It is not necessary that the two mutually associated and opposite side surfaces 12 have the exact same cone angle. The cone angle of one side surface may differ from the cone angle of the other side surface.

It is important that a recess which is open conically upwards is formed in the cavity 4, into which the tooth 10 is deformed in the form of a flow-pressing process.

Of course, the information given here refers to a punch 6, which moves in the direction of arrow 14 from top to bottom.

In another, kinematic reversal of the illustrated embodiment, however, it may also be provided that the punch 6 is arranged below and in the direction of arrow 14 moves upward.

The movements of the two mutually moving tool parts 6 and 7 in the directions of arrows 14 and 15 is synchronized so that when booting the lifter 7 in the direction of arrow 15 of the punch 6 in the direction of arrow 14 performs a faster movement down to the mentioned flow-pressing process in To trigger cavity 4.

The surface of the lifter 7 thus forms the mating surface of the deformed tooth 10, which is pressed into the cavity 4.

The FIG. 4 shows that with this flow-pressing operation opposite conical tooth flanks 17 are achieved.

The FIGS. 5a to 5d show a similar process as in the FIGS. 2 to 4 described, except that in addition a so-called roof mold 8 is stamped. Otherwise, the same names and the same functional sequence apply to the same parts.

The FIG. 5a shows in general that in a strip material 1, first, a flow preform 3 is applied as a cup-shaped impression.

Opposite now this cup-shaped flow preform 3 is a roof mold 8 is impressed, by a specially shaped stamp 6, as in FIG. 5c is shown.

This stamp has a conical recording, which corresponds to the later roof shape 8.

When moving together of the two tools 6, 7, the same flow-pressing operation is then carried out in the cavity 4, wherein, however, in FIG. 5c only a preform of the flow-pressing process is given, and not yet the final contour of the tooth 10 has been reached. Only after the final calibration to the final contour FIG. 5d then the final tooth shape of the component 2 in FIG. 5d reached.

The FIG. 6 shows such a tooth 10 with an impressed roof shape 8, wherein the roof shape is bordered by the two conical tooth flanks 17. The roof shape acts as an insertion bevel to achieve a softer switching of the synchronizer ring, coupling body or clutch disc when inserted into a tooth gap.

In Fig. 2 the fineblanking process is shown in section 2 in section. The strip material is clamped by the device 5 at a predefined pressure. Stamp 6 and ejector 7 cut after the completed pressure build-up of 5, the component 2 in the conical design of the lower part of the device 5. The pre-oriented material volume through the advanced flow prominence in the area 4 allows the flow of material into held cavities 4 and thus a burr-free component. Fig. 3 shows another variant. As in Fig. 2 1, a flow precursor is introduced, in the same or following stage, a specific roof shape is further introduced by flow projections. In the following stage, the in Fig. 2 described combined fine blanks with extrusion presses for preorientation of the material, in contrast to Fig. 2 does not yet represent the final contour. Only in the subsequent stage is the burr-free extruding and calibrating on the final contour of the stamped part 2 by punch 6 and lifter 7 and a die. 5

It should be noted that this method and the device is not limited to the production of synchronizer rings, coupling body or clutch disc. The method and apparatus are generally applicable to the manufacture of stampings.

Drawing web end

1

band material

2

Component (synchronizer ring)

3

flow preform

4

cavity

5

5a

Downholder (upper tool)

5b

Hold down (lower tool)

6

stamp

7

Lifters

8th

roof shape

8a

roof Spitz

9

tip circle

10

tooth

11

Width (from 3)

12

Side surface (conical)

13

Floor (cavity 11)

14

arrow

15

arrow

16

punch hole

17

Conical tooth flank

18

Flow material

Claims (23)

A method for producing stamped parts, in particular of synchronizer rings, coupling bodies or clutch plates, wherein in one step, the band material to be processed (1) between the hold-down (5a, 5b) is clamped a fine cutting tool, and embossed in a further process step, at least the teeth (10) be characterized in that in a first process step, a Fließvorprägen in the strip material (1) at least in the area of the later auschnchneidenden teeth (10) is carried out, and that subsequently takes place the step of fine blanking in conjunction with an extrusion in the strip material (1) , A method according to claim 1, characterized in that in the fine blanking process, a combined fine shearing and extrusion takes place in a single tool stage. A method according to claim 1 or 2, characterized in that the teeth are formed with a fine blanking process and simultaneously subjected to extrusion and thereby displaced into a free created by a pre-embossing volume (cold deformation). A method according to claim 1 to 3, characterized in that the extrusion in the combined cutting and extruding step takes place by creating a void volume (4) within the flow preform (3) which is filled by the extrusion process in the fine cutting stage. A method according to claim 1 to 4, characterized in that during a work step in the fine blanking stage, a first component (2) is preformed from raw material by Fließvorprägen and at the same time in the fine blanking stage in a second component, the fine blanking and extrusion are performed. The method of claim 1 to 5, characterized in that after completion of an operation, the first component (2) by means of a handling device from the flow preforming stage for fineblanking automatically by advancing the strip material (1) is transported and that the second component simultaneously removed from the device and the flow preforming stage is equipped with a new raw material. A method according to claim 1 to 6, characterized in that initially in the strip material (1) takes place a flow predisposition, and flow preforms (3) corresponding to the number of teeth (10) of the subsequently configured synchronizer ring (component 2) are impressed without durchzustanzen the strip material or hurt. A method according to claim 1 to 7, characterized in that the flow preforms (3) consist of cup-shaped depressions which are embossed in the strip material. A method according to claim 1 to 8, characterized in that the embossed cup corresponds in shape approximately to the later tooth of the synchronizer ring. A method according to claim 1 to 9, characterized in that the diameter of the root circle of the forms (flow preforms 3) of the diameter of the root circle of the later teeth (10) deviates, in particular is smaller. A method according to claim 1 to 10, characterized in that the diameter of the top circle of the forms is also smaller than the later head diameter (9) of the teeth (10) of the synchronizer ring (2). Method according to one of claims 1 to 11, characterized in that by the strip material (1) a punch (6) from above in the direction of arrow (14) down and at the same time from below a lifter (7) in the direction of arrow (15) moves upwards , wherein the two tools (6, 7) in the region of a cavity (4) meet, which is arranged in the hold-down (5b) of the lower tool. Device for producing stamped parts, in particular synchronizer rings, coupling bodies or clutch disc (2), wherein the band material (1) to be processed is clamped between the down holders (5a, 5b) of a fineblanking tool and at least the teeth (10) are embossed, characterized that the flow molding is arranged in the same tool as the device for fine blanking and simultaneous extrusion. Apparatus according to claim 13, characterized in that the flow preforms (3) consist of cup-shaped recesses which are embossed in the strip material (1) without tearing or opening the strip material (1) at this point. Device for carrying out the method according to one or more of claims 1-14, characterized in that the embossed cup corresponds in its shape approximately to the later tooth (10) of the synchronizer ring (2). Device according to one of claims 1-15, characterized in that the bottom is curved to achieve a smooth transition in the side walls of the cup-shaped Fließvorprägung. Device according to one of claims 1-16, characterized in that the diameter of the root circle of the manifestations deviates from the diameter of the root circle of the later teeth (10), in particular is smaller. Device according to one of claims 1-17, characterized in that the diameter of the top circle of the forms is also smaller than the later head diameter (9) of the teeth of the synchronizer ring (2). Device according to one of claims 1-18, characterized in that the cavity (4) with its side surfaces (12) is tapered, so that the cup-shaped flow preform (3) with its flow material (18) in this conical cavity (4 ) is pressed into it. Device according to one of claims 1-19, characterized in that the bottom (13) of the cavity (4) is formed cambered. Device according to one of claims 1-20, characterized in that the opposite side surfaces (12) do not have the same cone angle. Device according to one of claims 1-21, characterized in that by the punch (6), which has a conical receptacle, a so-called roof mold (8) on the strip material (1) is impressed. Device according to one of claims 1-22, characterized in that the tooth (10) with the embossed roof shape (8) by the two conical tooth flanks (17) is enclosed.

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