EP2307156A1 - Method of making a ring - Google Patents

Method of making a ring

Info

Publication number
EP2307156A1
EP2307156A1 EP09758660A EP09758660A EP2307156A1 EP 2307156 A1 EP2307156 A1 EP 2307156A1 EP 09758660 A EP09758660 A EP 09758660A EP 09758660 A EP09758660 A EP 09758660A EP 2307156 A1 EP2307156 A1 EP 2307156A1
Authority
EP
European Patent Office
Prior art keywords
blank
slit
ring
tooling
post
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP09758660A
Other languages
German (de)
French (fr)
Other versions
EP2307156B1 (en
Inventor
Yahya Hodjat
Anil Bhalla
Phil Richards
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Gates Corp
Original Assignee
Gates Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Gates Corp filed Critical Gates Corp
Publication of EP2307156A1 publication Critical patent/EP2307156A1/en
Application granted granted Critical
Publication of EP2307156B1 publication Critical patent/EP2307156B1/en
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/76—Making machine elements elements not mentioned in one of the preceding groups
    • B21K1/761—Making machine elements elements not mentioned in one of the preceding groups rings
    • 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
    • B21D53/16—Making other particular articles rings, e.g. barrel hoops
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/02—Die forging; Trimming by making use of special dies ; Punching during forging
    • B21J5/022—Open die forging

Definitions

  • the invention relates to a method of making a ring, and more particularly, to a method of making a ring by- expanding the middle of a slit blank while simultaneously applying a compressive force to ends of the blank.
  • Tubular rings are used for many applications in the industry. Rings can be broached, hobbed, machined, ground, or used as is for many applications. Applications include gears, starter gears, clutch hubs, sprockets, pulleys, crankshaft dampers, and many other products .
  • tubular rings There are many existing arts for manufacturing tubular rings. Some common methods include making a hoop from bar stock and welding the joint; making a tube and cutting it; deep drawing a cup and removing the face of the cup; expanding a blank in ring rolling, forging, casting, or spinning a blank from sheet metal.
  • Cut seamless tubes are expensive and making a cup in a press and removing the face creates excessive waste.
  • the sheared-off outer ring (44) is therefore ejected in the next to last stage, while in the last working stage the inner ring (45) separated from the outer ring is subjected to further working.
  • This last working stage involves stamping out a waste piece (35) and shearing-off an annular web (38) . It is also possible to carry out a forming operation in this last working stage to upset the remaining inner ring (22a) .
  • the radial annular web (38) can be supported over its full cross- sectional surface during the shearing-off operation. What is needed is a method of making a ring by expanding the middle of a slit blank while simultaneously applying a compressive force to ends of the blank. The present invention meets this need.
  • the primary aspect of the invention is to provide a method of making a ring by expanding the middle of a slit blank while simultaneously applying a compressive force to ends of the blank.
  • the invention comprises a method of making a ring comprising cutting a raw material stock to a predetermined length, cutting a slit through the raw material stock along its length to form a blank, inserting the blank into a tool, expanding the middle of the slit while simultaneously applying a compressive force to the ends of the blank, and expanding the middle of the slit until the blank is round.
  • Fig. 1 is a plan view of a blank.
  • Fig. 2 is a side of view of the blank in the tooling.
  • Fig. 3 is a side view of the blank in the tooling.
  • Fig. 4 is a perspective view of the blank at an intermediate step.
  • Fig. 5 is a side view of the blank in the tooling.
  • Fig. 6 is a perspective view of the finished ring.
  • Fig. 7 is a top perspective view of a blank in the tooling.
  • Fig. 8 is a top perspective view of the tooling.
  • Fig. 9 is a side perspective view of the tooling.
  • the invention comprises a process of manufacturing a tubular ring from bar stock.
  • a rectangular bar stock is preferred, any other configuration (round, hexagonal, etc.) may also be used.
  • Fig. 1 is a plan view of a blank.
  • the process starts with a raw material such as a simple bar stock from which is cut a blank 10 having the desired length (L) and width (W) .
  • Raw materials may comprise other than bar stock, including flats, rounds, or any other available form of metal material .
  • a rectangular bar stock is used.
  • the four corners 11 at the ends of the cut rectangular blank are rounded using known processes to facilitate the process and to give the blank a uniform thickness.
  • the blank is cut to form a slit 12 in the middle extending in the longitudinal direction (along its length) .
  • the slit can be cut using a laser or other cutting means which include but not limited to: high pressure water jet, laser, plasma, abrasive cutters, milling, or other means.
  • a radius 13 At each end of the slit is a radius 13 to prevent crack formation in the expansion process and to keep the thickness uniform.
  • the width of the slit is kept to a minimum to reduce waste.
  • Fig. 2 is a side of view of the blank in the tooling.
  • the blank 10 is then introduced into a press.
  • a contoured thickening and rounding post 20 is pressed into the blank at the slit which opens and expands the slit.
  • the post initially contacts the slit in the middle.
  • End 22 of post 20 comprises a blade which engages the slit 12.
  • Post 20 is pressed though blank 10 into a receiving female die 21 using a known hydraulic
  • the maximum outside diameter of the post 20 substantially matches the desired inner diameter of the finished ring, see Fig. 6, minus any machining that may be required.
  • Fig. 3 is a side view of the blank in the tooling.
  • Fig. 4 is a perspective view of the blank at an intermediate step. Slit 12 is shown partially opened. The full diameter of post 20 has not yet engaged the blank 10 and so it is not yet fully rounded. Shoes 23, 24 engage ends 101, 102 of the blank.
  • Fig. 5 is a side view of the blank in the tooling.
  • the full outside diameter of post 20 is shown fully engaged with the blank 10.
  • Blank 10 is therefore fully round.
  • Shoes 23, 24 are pressed about blank 10 in order to control the forming and to avoid "squaring" of the blank.
  • Fig. 6 is a perspective view of the finished ring.
  • the ID of ring 10 substantially matches the OD of the post 20.
  • the ring is formed on the post, it is ejected and it is ready to use. If desired and required it is ready for final operations, for example, machining, rolling, spinning, forging, sizing, grinding, etc.
  • the formed ring can then sized in an ironing die in a press to obtain a very accurate size and/or a very fine surface finish.
  • Yet another version of the method shows that the blank can be expanded to the somewhat square shape and then rounded in a simple rotary forging operation.
  • Other embodiments include taking the square blank and spinning it into a round ring, or using a ring rolling process to achieve a round ring.
  • the ring can either be formed to a round final shape, or it can be introduced to the press tooling again for a final sizing and rounding operation.
  • the need for these additional operations increases as harder material is used, e.g., alloy steels or high carbon steels.
  • Harder steels can be formed with the described press tooling, but, they may require larger diameters at the end of the inner slit to prevent cracking. They may also require hot forming (usually 600 to 1100 degrees
  • the geometrical aspects of the parent bar stock namely the length, radii around the outer edges, the diameter of the rounded radii at the ends of the slit and the slit thickness are all relevant variables which can be easily selected to optimize accuracy with minimum offal.
  • the design of the tooling is also relevant to reduce complexity.
  • the tooling can comprise one long post with an expandable lower tooling or a few press stations with gradually expanding lower tooling and gradually thickening and rounding upper tooling.
  • the pre-form blank may be made in a "dog bone" shape, where very large diameters at the ends of the slit will allow an easy forming process at the ends of the slit area.
  • Fig. 7 is a top perspective view of a blank in the tooling.
  • Blank 10 is shown staged in collar 25.
  • Collar 25 controls the position of the blank prior to and during the forming process.
  • Shoes 23, 24 are each shown withdrawn in order to allow blank 10 to be inserted between.
  • Members 27, 26 support the blank between shoes 23, 24.
  • Fig. 8 is a top perspective view of the tooling.
  • Blank 10 is removed to give a better view of the members 26, 27.
  • Members 26, 27 apply a force in a vector direction normal to the compressive force vector of shoes 23, 24 and simultaneously withdraw, or move apart from each other in concert with post 20 as post 20 is pressed through the slit in blank 10. This provides the necessary support for blank 10 as it is formed.
  • members 26, 27 support the blank to prevent an axial deformation that is normal to the direction of expansion of the slit. This prevents the blank from deforming in the direction of movement of post 20.
  • the movement of post 20 is characterized as movement in an axial direction.
  • Fig. 9 is a side perspective view of the tooling.
  • Post 20 is shown at the beginning of insertion into slit 12.
  • Blade 22 is shown engaged with slit 12.
  • Post 20 is pressed into slit 12, thereby expanding the middle of the slit while shoes 23, 24 simultaneously compress the ends of the blank.
  • Post 20 is pressed into the blank 10, thereby continuing to expand the middle of the slit until the blank is round.
  • Post 20 is then withdrawn and the formed ring is ejected.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)
  • Pistons, Piston Rings, And Cylinders (AREA)
  • Rolling Contact Bearings (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)

Abstract

A method of making a ring comprising cutting a raw material stock to a predetermined length, cutting a slit through the raw material stock along its length to form a blank, inserting the blank into a tool, expanding the middle of the slit while simultaneously applying a compressive force to the ends of the blank, and expanding the middle of the slit until the blank is round.

Description

Title Method of Making a Ring
Field of the Invention
The invention relates to a method of making a ring, and more particularly, to a method of making a ring by- expanding the middle of a slit blank while simultaneously applying a compressive force to ends of the blank. r ■• t
Background of the Invention
Tubular rings are used for many applications in the industry. Rings can be broached, hobbed, machined, ground, or used as is for many applications. Applications include gears, starter gears, clutch hubs, sprockets, pulleys, crankshaft dampers, and many other products .
There are many existing arts for manufacturing tubular rings. Some common methods include making a hoop from bar stock and welding the joint; making a tube and cutting it; deep drawing a cup and removing the face of the cup; expanding a blank in ring rolling, forging, casting, or spinning a blank from sheet metal.
All of these processes are suitable, but the cost or quality of the produced ring is always a problem. For example, welded hoops have problems in the weld area when the ring is flow formed further to make gears, pulleys, splined rings, etc. Further, the welding and cleaning the weld and/or heat treating to normalize the weld area is costly.
Cut seamless tubes are expensive and making a cup in a press and removing the face creates excessive waste.
Representative of the art is US patent no. 4,590,780 which discloses a process starting from a pre-heated bar, there is sheared-off first a portion (41) which, in a first forming stage of the machine, is formed into a tier shaped pressed article. In the second forming stage, the pressed article is further formed so that it has an inner ring (J) , an outer ring (A) arranged co-axially to this and a radial annular web (S) connecting the two rings
(J, A) . The sheared-off outer ring (44) is therefore ejected in the next to last stage, while in the last working stage the inner ring (45) separated from the outer ring is subjected to further working. This last working stage involves stamping out a waste piece (35) and shearing-off an annular web (38) . It is also possible to carry out a forming operation in this last working stage to upset the remaining inner ring (22a) . By means of this process which provides for the elimination of the finished outer ring (44) in the last working stage, the radial annular web (38) can be supported over its full cross- sectional surface during the shearing-off operation. What is needed is a method of making a ring by expanding the middle of a slit blank while simultaneously applying a compressive force to ends of the blank. The present invention meets this need.
Summary of the Invention
The primary aspect of the invention is to provide a method of making a ring by expanding the middle of a slit blank while simultaneously applying a compressive force to ends of the blank. Other aspects of the invention will be pointed out or made obvious by the following description of the invention and the accompanying drawings.
The invention comprises a method of making a ring comprising cutting a raw material stock to a predetermined length, cutting a slit through the raw material stock along its length to form a blank, inserting the blank into a tool, expanding the middle of the slit while simultaneously applying a compressive force to the ends of the blank, and expanding the middle of the slit until the blank is round.
Brief Description of the Drawings
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate preferred embodiments of the present invention, and together with a description, serve to explain the principles of the invention.
Fig. 1 is a plan view of a blank. Fig. 2 is a side of view of the blank in the tooling.
Fig. 3 is a side view of the blank in the tooling.
Fig. 4 is a perspective view of the blank at an intermediate step.
Fig. 5 is a side view of the blank in the tooling. Fig. 6 is a perspective view of the finished ring.
Fig. 7 is a top perspective view of a blank in the tooling.
Fig. 8 is a top perspective view of the tooling.
Fig. 9 is a side perspective view of the tooling.
Detailed Description of the Preferred Embodiment
The invention comprises a process of manufacturing a tubular ring from bar stock. Although a rectangular bar stock is preferred, any other configuration (round, hexagonal, etc.) may also be used.
The manufactured ring may be used in making gears, pulleys, sprockets, bearing races, one-way clutch races crankshaft damper inertia rings and similar products. Fig. 1 is a plan view of a blank. The process starts with a raw material such as a simple bar stock from which is cut a blank 10 having the desired length (L) and width (W) . Raw materials may comprise other than bar stock, including flats, rounds, or any other available form of metal material . For the purpose of this example a rectangular bar stock is used. The four corners 11 at the ends of the cut rectangular blank are rounded using known processes to facilitate the process and to give the blank a uniform thickness.
The blank is cut to form a slit 12 in the middle extending in the longitudinal direction (along its length) . The slit can be cut using a laser or other cutting means which include but not limited to: high pressure water jet, laser, plasma, abrasive cutters, milling, or other means. At each end of the slit is a radius 13 to prevent crack formation in the expansion process and to keep the thickness uniform. The width of the slit is kept to a minimum to reduce waste. Fig. 2 is a side of view of the blank in the tooling. The blank 10 is then introduced into a press. A contoured thickening and rounding post 20 is pressed into the blank at the slit which opens and expands the slit. The post initially contacts the slit in the middle. End 22 of post 20 comprises a blade which engages the slit 12. Post 20 is pressed though blank 10 into a receiving female die 21 using a known hydraulic ram 200.
Use of a lower support die 21 that is as large as the final size of the ID of the ring, the blank will expand to a certain extent, about 50%, but it tends to bend and does not continue to expand in a single plane. Therefore, in order to have proper support for the blank as it is being expanded and to prevent it from bending during forming, either an expandable (sliding) lower tooling support tooling or a multi station tooling with gradually larger lower tooling opening and thicker and rounder post may be used as described herein.
The maximum outside diameter of the post 20 substantially matches the desired inner diameter of the finished ring, see Fig. 6, minus any machining that may be required.
Fig. 3 is a side view of the blank in the tooling.
Since tensile forces are not desirable in metal forming r~ - and compressive forces are desirable, in order to prevent pulling the ends apart and causing failure the instant process pushes, that is, applies a compressive force simultaneously to the ends of the blank as it is also being expanded by the post 20. Applying compressive forces to ends 101, 102 of blank 10 while driving the post 20 into the slit gradually forms the blank into a round ring. The compressive force is applied to ends 101, 102 of the blank through shoes 23, 24. Shoes 23, 24 are pressed by known hydraulic rams 201 and 202 in a manner known in the art.
Fig. 4 is a perspective view of the blank at an intermediate step. Slit 12 is shown partially opened. The full diameter of post 20 has not yet engaged the blank 10 and so it is not yet fully rounded. Shoes 23, 24 engage ends 101, 102 of the blank.
Fig. 5 is a side view of the blank in the tooling. The full outside diameter of post 20 is shown fully engaged with the blank 10. Blank 10 is therefore fully round. Shoes 23, 24 are pressed about blank 10 in order to control the forming and to avoid "squaring" of the blank. Fig. 6 is a perspective view of the finished ring. The ID of ring 10 substantially matches the OD of the post 20.
Once the ring is formed on the post, it is ejected and it is ready to use. If desired and required it is ready for final operations, for example, machining, rolling, spinning, forging, sizing, grinding, etc. The formed ring can then sized in an ironing die in a press to obtain a very accurate size and/or a very fine surface finish.
Yet another version of the method shows that the blank can be expanded to the somewhat square shape and then rounded in a simple rotary forging operation. Other embodiments include taking the square blank and spinning it into a round ring, or using a ring rolling process to achieve a round ring.
Further, the ring can either be formed to a round final shape, or it can be introduced to the press tooling again for a final sizing and rounding operation. The need for these additional operations increases as harder material is used, e.g., alloy steels or high carbon steels. Harder steels can be formed with the described press tooling, but, they may require larger diameters at the end of the inner slit to prevent cracking. They may also require hot forming (usually 600 to 1100 degrees
Celsius) , or warm forming (up to 600 degrees Celsius) .
The geometrical aspects of the parent bar stock, namely the length, radii around the outer edges, the diameter of the rounded radii at the ends of the slit and the slit thickness are all relevant variables which can be easily selected to optimize accuracy with minimum offal.
The design of the tooling is also relevant to reduce complexity. The tooling can comprise one long post with an expandable lower tooling or a few press stations with gradually expanding lower tooling and gradually thickening and rounding upper tooling. Furthermore, to prevent failure at the ends of the slit for very hard material, the pre-form blank may be made in a "dog bone" shape, where very large diameters at the ends of the slit will allow an easy forming process at the ends of the slit area.
Fig. 7 is a top perspective view of a blank in the tooling. Blank 10 is shown staged in collar 25. Collar 25 controls the position of the blank prior to and during the forming process. Shoes 23, 24 are each shown withdrawn in order to allow blank 10 to be inserted between. Members 27, 26 support the blank between shoes 23, 24.
Shoes 23, 24 in Figs. 7, 8, 9 are the same as those shown in Figs . 2 , 3 , 5.
Fig. 8 is a top perspective view of the tooling. Blank 10 is removed to give a better view of the members 26, 27. Members 26, 27 apply a force in a vector direction normal to the compressive force vector of shoes 23, 24 and simultaneously withdraw, or move apart from each other in concert with post 20 as post 20 is pressed through the slit in blank 10. This provides the necessary support for blank 10 as it is formed. Put another way, members 26, 27 support the blank to prevent an axial deformation that is normal to the direction of expansion of the slit. This prevents the blank from deforming in the direction of movement of post 20. The movement of post 20 is characterized as movement in an axial direction.
Fig. 9 is a side perspective view of the tooling. Post 20 is shown at the beginning of insertion into slit 12. Blade 22 is shown engaged with slit 12. Post 20 is pressed into slit 12, thereby expanding the middle of the slit while shoes 23, 24 simultaneously compress the ends of the blank. Post 20 is pressed into the blank 10, thereby continuing to expand the middle of the slit until the blank is round. Post 20 is then withdrawn and the formed ring is ejected.
Although forms of the invention have been described herein, it will be obvious to those skilled in the art that variations may be made in the construction and relation of parts without departing from the spirit and scope of the invention described herein.

Claims

Claims We claim:
1. A method of making a ring comprising: cutting a raw material stock to a predetermined length; cutting a slit through the raw material stock along its length to form a blank; inserting the blank into a tool; expanding the middle of the slit while simultaneously applying a compressive force to the ends of the blank; and expanding the middle of the slit until the blank is round .
2. The method as in claim 1 further comprising supporting the blank in a direction that is normal to the simultaneously applied compressive force.
3. The method as in claim 1 further comprising cutting a radius at each end of the slit.
4. The method as in claim 1 further comprising: ejecting the formed blank from the tool; and finishing the formed blank to a final size and form.
5. The method as in claim 1 further comprising supporting the blank to prevent an axial deformation that is normal to the direction of expansion of the slit.
EP09758660A 2008-06-06 2009-05-15 Method of making a ring Not-in-force EP2307156B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US12/157,013 US20090301162A1 (en) 2008-06-06 2008-06-06 Method of making a ring
PCT/US2009/003059 WO2009148496A1 (en) 2008-06-06 2009-05-15 Method of making a ring

Publications (2)

Publication Number Publication Date
EP2307156A1 true EP2307156A1 (en) 2011-04-13
EP2307156B1 EP2307156B1 (en) 2011-10-19

Family

ID=41022556

Family Applications (1)

Application Number Title Priority Date Filing Date
EP09758660A Not-in-force EP2307156B1 (en) 2008-06-06 2009-05-15 Method of making a ring

Country Status (10)

Country Link
US (1) US20090301162A1 (en)
EP (1) EP2307156B1 (en)
JP (1) JP5501348B2 (en)
KR (1) KR101216239B1 (en)
CN (1) CN102056688B (en)
AT (1) ATE529205T1 (en)
BR (1) BRPI0913120A2 (en)
CA (1) CA2725746C (en)
RU (1) RU2468884C2 (en)
WO (1) WO2009148496A1 (en)

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DE102009022392B4 (en) * 2009-05-22 2011-09-22 Federal-Mogul Sealing Systems Gmbh Method for producing metal stopper elements for flat gaskets
JP5645536B2 (en) * 2010-08-09 2014-12-24 ユニプレス株式会社 Annular disk molding material, annular disk molding method and mold
CN102513442B (en) * 2011-11-24 2014-02-05 贵州安大航空锻造有限责任公司 Method for forming irregular ring piece by utilizing high-temperature alloy rectangular ring rolled piece through thermal bulging
CN102513780A (en) * 2011-12-22 2012-06-27 西南铝业（集团）有限责任公司 Forging process of large forged ring
JP6082263B2 (en) * 2013-02-13 2017-02-15 中央発條株式会社 Manufacturing method of annular member
JP6179796B2 (en) * 2013-03-22 2017-08-16 日立金属株式会社 Die for hot forging and hot forging method
DE102014115727B3 (en) * 2014-10-29 2016-04-21 Hugo Benzing Gmbh & Co. Kg Method for producing a clamping ring
RU2624882C2 (en) * 2015-12-14 2017-07-07 Федеральное государственное унитарное предприятие "Государственный космический научно-производственный центр им. М.В. Хруничева" Method of manufacturing ring
CN107138550A (en) * 2017-03-27 2017-09-08 刘金财 Low cost prepares the method that surface scribbles the large-sized aluminium alloy sheet material of wearing layer
CN108608209A (en) * 2018-03-30 2018-10-02 温州市华海密封件有限公司 The processing method of monoblock type metal ring product
CN111822649B (en) * 2020-07-16 2021-06-04 江阴方圆环锻法兰有限公司 Forging process of high-precision forge piece

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Also Published As

Publication number Publication date
CN102056688A (en) 2011-05-11
US20090301162A1 (en) 2009-12-10
JP5501348B2 (en) 2014-05-21
KR101216239B1 (en) 2012-12-28
RU2010154100A (en) 2012-07-20
KR20110005310A (en) 2011-01-17
ATE529205T1 (en) 2011-11-15
RU2468884C2 (en) 2012-12-10
EP2307156B1 (en) 2011-10-19
JP2011521791A (en) 2011-07-28
WO2009148496A1 (en) 2009-12-10
BRPI0913120A2 (en) 2016-01-05
CA2725746C (en) 2013-07-02
CN102056688B (en) 2013-03-27
CA2725746A1 (en) 2009-12-10

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