JP2733651B2 - Method of manufacturing sheet metal poly-V groove pulley - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a sheet metal poly-V groove pulley.

[0002]

2. Description of the Related Art A sheet metal poly-V groove pulley of this type is often used by being interposed in a rotation transmission path between an engine and a load. This poly V-groove pulley has V-grooves formed annularly at a plurality of locations in the cylindrical body wall in the axial direction, and axially outwards at one end and the other end in the axial direction on the body wall. A flange-shaped ear portion whose diameter is increased toward the center is provided.

[0003] Poly-V groove pulleys of the type described above, for example,
It can be manufactured using a sheet metal material obtained by subjecting a steel sheet or the like to necessary processing such as drawing or rubbing against an end face.

A conventional method of manufacturing a sheet metal poly-V groove pulley will be described with reference to FIGS. FIG. 5 partially shows the sheet metal material. In the sheet metal material 1, a cylindrical body wall 3 is integrally provided on the outer periphery of a disk-shaped substrate portion 2, and an axial direction of the body wall 3 is provided. Both ends are provided with flange-shaped rough ears 4, 4, respectively. Further, the surface of the substrate portion 2 and the inner peripheral surface of the body wall 3 are connected via curved surfaces 5 and 5. The sheet metal material 1 of FIG. 5 is held in a rotary mold, and in this state, a poly-V groove is formed on the outer peripheral surface of the body wall 3, and
The coarse ears 4, 4 are finished into ears 7, 7 having a predetermined shape.

FIGS. 6 and 7 show the formation of the poly V groove and the ear portions 7 and 7.
Is shown in two stages. In this step, the groove forming roller 300 is used. The groove forming roller 300 includes a plurality of ridge forming surfaces 301 for forming a poly V groove and a valley forming surface 302 between the ridge forming surfaces 301.
And ear molding surfaces 303, 303. In addition, the lower rotary mold 100 and the upper rotary mold 200 used in this step have molding surfaces 101, 2 supporting the inner peripheral surface of the body 3 of the material 1.
01 and ear molding surfaces 102 and 202 are provided. In this step, the groove forming roller 300 is pressed against the outer peripheral surface of the body wall 3 of the material 1, and the outer circumferential surface of the body wall 3 of the material 1 is rotated while rotating the material 1 and the groove forming roller 300. The coarse V-groove 6 is gradually formed into a predetermined shape by forming the poly-V groove 6 to gradually increase the depth of the poly-V groove 6, thereby forming the lug 7,7. . 6 and 7, the arrow A indicates the groove forming roller 5.
10 represents the pressing direction.

[0006]

However, in the sheet metal poly-V groove pulley employing the above-described conventional manufacturing method, the individual groove ridges forming the poly V groove 6 as shown in FIG. Wrinkles 6 at the top of 61, probably due to meat wrapping
2 were found, and also, as shown in FIG. 9, there was found a thinned portion 63 at the top of the groove ridge 61.

Further, the groove forming roller 300 used in the conventional manufacturing method has a problem that its service life is extremely short.

Therefore, the inventor of the present application has conducted intensive studies in order to investigate the causes thereof, and has found out that the following phenomena have occurred in the step of forming the poly-V groove 6 and the ear 7.

That is, in the conventional manufacturing method, as shown in FIGS. 6 and 7, in the forming process of the poly-V groove 6 and the lug 7, the cylinder of the sheet metal material 1 is always kept from the initial stage to the final stage. Molding surfaces 101, 201 of lower rotary mold 100 and upper rotary mold 200 corresponding to inner peripheral surfaces 31, 31 of wall 3
Are in contact with the inner peripheral surfaces 31, 31, and as the mountain-formed surface 301 of the groove forming roller 300 is pushed into the body wall 3, the thickness of the body wall 3 is changed as indicated by the arrow. A reference line A- set at a location in contact with the outer peripheral surface of the sheet metal material 1
A, and flows toward both sides of the crest-shaped surface 301 such that the flow of meat is
As shown by an arrow in FIG. 8, the above-mentioned groove ridge 61 is formed in a protruding shape at the bottom of the groove, or in some cases, the meat does not reach the bottom of the valley forming surface 302. I found out that.

The inventor of the present application has found that the wrinkles 62 at the top of the groove 61 as shown in FIG. 8 are caused by the flesh flowing toward both sides of the peak forming surface 301 beyond the reference line AA. It is guessed that it is caused by being caught in the bottom of the valley-formed surface 302. The underfilled portion 63 at the top of the groove 61 as shown in FIG. It was speculated that this was caused by the inability of the meat to reach. Further, the reason why the service life of the groove forming roller 300 is extremely short was presumed to be because the load applied to the groove forming roller 300 when forming the poly V groove 6 and the ear portion 7 was excessive. . In FIGS. 6 and 7, a1-a1 represents the lower rotary mold 100 and the upper rotary mold 20.
It is a line indicating the position of the molding surfaces 101 and 201 of 0.

The present invention has been made under the above circumstances. That is, according to the present invention, the poly-V groove is formed only by causing the ridge forming surface of the groove forming roller to bite into the body wall of the sheet metal material without causing almost any bulge on the outer peripheral surface of the body wall of the sheet metal material. By taking such measures as possible, wrinkles that are considered to be caused by the inclusion of meat at the top of the groove crests do not occur, and the underfill portions 63 do not occur at the tops of the groove crests, and It is another object of the present invention to provide a method of manufacturing a sheet metal V-groove pulley capable of extending the service life of a groove forming roller.

[0012]

According to a first aspect of the present invention, there is provided a method of manufacturing a sheet metal poly V-groove pulley, comprising a cylindrical body wall having flange-shaped rough ears at both axial ends thereof. Forming a poly-V groove on the outer peripheral surface of the body wall of the material while rotating the material and the groove forming roller by pressing a groove forming roller against the outer peripheral surface of the body wall while holding the roller in a rotary mold. A method of manufacturing a sheet metal poly-V groove pulley, comprising: forming a gap between a rotary mold and an inner peripheral surface of the body wall;
The step of forming the groove is repeated a plurality of times to gradually increase the depth of the poly-V groove formed in the body wall of the material, so that the gap is reduced in diameter as the step proceeds. In this method, the rotary mold is sequentially replaced with a rotary mold having a smaller diameter of the forming surface corresponding to the inner peripheral surface of the body wall each time the above process is modified.

According to a second aspect of the present invention, in the method of manufacturing a sheet metal poly-V groove pulley, a cylindrical body wall is integrally provided on the outer periphery of the disk-shaped substrate portion, and the surface of the substrate portion and the inside of the body wall are formed. 2. The method for manufacturing a sheet metal poly V-groove pulley according to claim 1, wherein a sheet metal material whose peripheral surface is connected via a curved surface is used. Is a method of sequentially replacing a rotary mold having a curved molding surface corresponding to the above with a rotary mold having a large radius of curvature of the curved molding surface.

[0014]

According to the method of the present invention, when the step of forming the poly-V groove is repeated, a gap formed between the rotary mold and the inner peripheral surface of the body wall is formed in each step. ,
It serves as a flesh escape when forming a poly-V groove by making a groove forming roller bite into the outer peripheral surface of the body wall made of a sheet metal material. That is, when the groove forming roller bites into the outer peripheral surface of the body wall made of a sheet metal material, the meat flows toward the gap, and the depth of the poly-V groove is deepened with the flow of the meat. Therefore, the outer peripheral surface of the body wall hardly rises. In extreme terms, the top of the groove ridge of the manufactured sheet metal poly-V groove pulley is formed by the outer peripheral surface of the body wall remaining as it is. In addition, the load applied to the groove-forming roller is reduced because the sheet metal material disperses the load by reducing the diameter of its body wall by itself in each process.

According to the second aspect of the present invention, the radius of curvature of the curved surface connecting the surface of the substrate portion and the inner peripheral surface of the body wall increases each time the step of forming the poly-V groove is changed. Therefore, the flow of the meat into the gap is smoothly performed.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 partially shows a sheet metal material. In this sheet metal material 1, a cylindrical body wall 3 is integrally provided on the outer periphery of a disk-shaped substrate portion 2, At both ends in the axial direction of the body wall 3, flange-shaped coarse ears 4, 4 are provided, respectively.
Further, the surface of the substrate portion 2 and the inner peripheral surface of the body wall 3 are curved surfaces 5,
5 is connected. Here, a line in contact with the outer peripheral surface of the body wall 3 is illustratively shown as a reference line AA.

The sheet metal material 1 is held in a rotary mold. In this state, a poly-V groove is formed on the outer peripheral surface of the body wall 3 and the coarse ears 4 and 4 are formed in a predetermined shape. Finished at 7.

FIG. 2 and FIG. 3 show the formation of the poly V groove 6 and the
7 are shown separately and separately, and FIG. 2 shows a step performed first, and FIG.
Indicates a step performed after the first step.

The groove forming roller 300 'used in the first step shown in FIG. 2 has a plurality of peak forming surfaces 301', valley forming surfaces 302 ', and ear forming surfaces 303', 303 '. ing. Also, the lower rotary mold 10 used in this step is used.
0 ′ and the upper rotary mold 200 ′ are provided with molding surfaces 101 ′, 201 ′ and ear molding surfaces 102 ′, 202 ′ corresponding to the inner peripheral surface 31 of the body 3 of the material 1. In this step, the inner peripheral surface 3 of the body wall 3 indicated by a virtual line in FIG.
In the state where a predetermined gap C1 is formed between each of the molding surfaces 101 'and 201' of the lower rotary mold 100 'and the upper rotary mold 200', the substrate portion 2 of the material 1 is moved to the lower rotary mold 10 '.
0 'and the upper rotary mold 200', the material 1 is held. In this state, the groove forming roller 300 'is pressed against the outer peripheral surface of the body wall 3, and the material 1 and the groove forming roller 30 are pressed.
The gap C1 is reduced with the progress of the above process by forming a poly-V groove 6 on the outer peripheral surface of the body wall 3 of the material 1 while rotating 0 ′ and gradually increasing the depth of the poly-V groove 6. It is filled with the above-mentioned trunk wall 3 to be radiated. In parallel with this,
The coarse ears 4 and 4 are gradually finished in a predetermined shape to approximate the shape of the ears 7 and 7 (FIG. 3).

In this way, the gap C1 is
When the groove 6 is formed, it serves as an escape for meat, and when the ridge-forming surface 301 'of the groove forming roller 300' bites into the body wall 3, the meat flows toward the gap, and the meat flows. , The depth of the poly V groove is increased, and the outer peripheral surface of the body wall 3 hardly rises. That is, the flesh of the body wall 3 does not protrude beyond the reference line A-A, and even if it does,
There is no bulge that would cause wrinkles due to meat entrainment.
In addition, the material 1 itself is the inner peripheral surface 31 of the body wall 3.
Is reduced from a line a1-a1 indicating the position of the inner peripheral surface when the material 1 is held by the upper and lower rotary molds to a position of a line a2-a2 indicating the position of the molding surface of the upper and lower rotary molds. Since the load is distributed, the load applied to the groove forming roller 300 'is small, and the load does not cause a situation in which the service life of the groove forming roller 300' is significantly shortened.

After the poly V groove 6 and the coarse ears 4 and 4 are preformed in this manner, the material 1 is separated from the lower rotary mold 10 shown in FIG.
0 "and the upper rotary mold 200". The lower rotary mold 100 "and the upper rotary mold 200" used here are shown in FIG.
The diameters of the molding surfaces 101 ″ and 201 ″ are slightly smaller than those of the lower rotary mold 100 ′ and the upper rotary mold 200 ′ used in the first step described in FIG. Then, the inner peripheral surfaces 31 and 31 of the body wall 3 shown by phantom lines in FIG.
0 "and the molding surfaces 101", 20 "of the upper rotary mold 200".
In a state where a predetermined gap C2 is formed between the lower rotating mold 100 "and the upper rotating mold 200", the substrate portion 2 of the material 1 is formed.
The material 1 is held between the material 1 and the material 1 while being pressed against the outer peripheral surface of the body wall 3 while rotating the material 1 and the groove forming roller 300 ″. A poly-V groove 6 is formed on the outer peripheral surface of the body wall 3, and the poly-V groove 6 is gradually deepened, so that the gap C2 is filled with the body wall 3 whose diameter is reduced as the above process proceeds.
At the same time, the coarse ears 4 and 4 are formed and the ears 7 and 4 are formed.
Finish to 7.

In the step shown in FIG.
Is the escape of meat when molding the poly V groove 6,
The flesh of the torso wall 3 hardly rises beyond the reference line AA, and if it does, it rises only slightly and does not rise enough to cause wrinkles due to the winding of the meat. In addition, the material 1 itself, the inner peripheral surface 31 of the body wall 3,
31 is reduced in diameter from a line a2-a2 indicating the position of the inner peripheral surface when the material 1 is held by the upper and lower rotary molds to a position of a line a3-a3 indicating the position of the molding surface of the upper and lower rotary molds Therefore, the load applied to the groove forming roller 300 ″ is small, and the load does not significantly shorten the service life of the groove forming roller 300 ″.

In this embodiment, FIG.
The upper and lower rotary molds 100 ″, 20 used in the process described in
The radius of curvature of the curved forming surface 103 "provided in the upper and lower rotary molds 1 used in the first step described with reference to FIG.
Curved forming surface 103 'provided on 00', 200 '
Is larger than the radius of curvature. The curvature radius of the curved molding surface 103 'provided in the upper and lower rotary molds 100' and 200 'used in the first step described with reference to FIG. 2 is the curvature radius of the curved surface 5 of the material 1 shown in FIG. Larger than radius. For this reason, the curvature radius of the curved surface 5 of the material 1 shown in FIG. 1 becomes slightly larger through the process described in FIG.
Furthermore, the radius of curvature of the curved surface 5 of the raw material 1 obtained through the steps described with reference to FIG. 2 is further increased through the steps described with reference to FIG. As described above, when the radius of curvature of the curved surface 5 is gradually increased in each step of advancing the forming of the poly-V groove 6, the flow of the meat to the gaps C1 and C2 is smoothly performed in each step. And the load on the groove forming rollers 300 ′ and 300 ″ is further reduced.

FIG. 4 shows the outline of the inner peripheral surface 31 of the raw material 1, the outline of the poly-V groove 6, the outline of the coarse ear 4 or the ear 7, and the outline of the curved surface 5 at each stage described above. It is a diagram in which the behavior at the time of molding the poly-V groove 6 can be grasped easily by superimposing and displaying. In the same figure, the material 1 at the stage shown in FIG.
A thin solid line b represents the material 1 having undergone the step shown in FIG. 2, and a thick solid line c represents the poly V groove pulley having undergone the step of FIG.

[0025]

As described above, according to the method of the present invention, a poly-V groove can be formed on a body wall of a sheet metal material without an unreasonable bulge due to a flow of meat. Therefore, it is possible to easily manufacture a sheet metal poly-V groove pulley having no wrinkles or missing portions at the tops of the groove peaks. Further, when forming the poly-V groove, since the flesh flows and escapes in the gap between the rotary mold and the inner peripheral surface of the body wall of the sheet metal material, the load applied to the groove forming roller is reduced, and the molding is performed accordingly. The service life of the groove roller is improved. In particular, in the method of the present invention, the step of forming the poly-V groove in a state where a gap is formed between the rotary mold and the inner peripheral surface of the body wall is repeated a plurality of times, and the poly-V groove formed on the body wall of the material is repeated. By gradually increasing the depth of the above, the gap is filled in each step by the above-mentioned body wall which is reduced in diameter with the progress of the above-mentioned steps, and each time the above-mentioned steps are changed, the rotating mold is Since it adopts a means of replacing the rotary mold with a smaller forming surface diameter corresponding to the inner peripheral surface of the body wall, a sheet metal poly-V groove pulley having no wrinkles or underfills at the top of the groove ridge. Can be easily and easily manufactured. According to the second aspect of the present invention, the degree of reduction of the load applied to the groove forming roller is increased, and the service life of the groove forming roller is further improved.

[Brief description of the drawings]

FIG. 1 is an explanatory view partially showing a specific shape of a sheet metal material used in a method of manufacturing a sheet metal poly-V groove pulley according to the present invention.

FIG. 2 is an explanatory view of the first step in the method for manufacturing a sheet metal poly-V groove pulley according to the present invention.

FIG. 3 is an explanatory view of the next step in the method of manufacturing a sheet metal poly-V groove pulley according to the present invention.

FIG. 4 is an explanatory diagram showing the behavior of each contour line in the method of manufacturing a sheet metal poly-V groove pulley according to the present invention.

FIG. 5 is an explanatory view partially showing a specific shape of a sheet metal material used in a conventional method.

FIG. 6 is an explanatory diagram of an intermediate stage in a conventional method.

FIG. 7 is an explanatory diagram of a final stage in a conventional method.

FIG. 8 is an explanatory view showing a defect generated in a groove crest of a sheet metal poly-V groove pulley manufactured by a conventional method.

FIG. 9 is an explanatory view showing another defect generated in a groove crest of a sheet metal poly-V groove pulley manufactured by a conventional method.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 sheet metal material 3 trunk wall 4 rough ear part 5 curved surface 6 poly V groove 31 inner peripheral surface of trunk wall 100 ′, 100 ″ lower rotary mold 101 ′, 101 ″ molding surface 103 ′, 103 ″ curved molding surface 200 ′ , 200 "Upper rotary mold 201 ', 201" Molding surface 300', 300 "Groove forming rollers C1, C2 Clearance

Claims (2)

(57) [Claims] 1. A groove forming roller is pressed against the outer peripheral surface of a cylindrical body wall in a state where a sheet metal material having flange-shaped rough ears at both axial ends of a cylindrical body wall is held in a rotary mold. A method for manufacturing a sheet metal poly-V groove pulley, comprising forming a poly-V groove on an outer peripheral surface of a body wall of the material while rotating the material and a groove forming roller. The step of forming the poly-V groove with the gap formed between the inner wall surface and the inner peripheral surface is repeated a plurality of times to gradually increase the depth of the poly-V groove formed in the body wall of the material, thereby forming the gap. Is filled in each step by the body wall which is reduced in diameter with the progress of the above steps, and each time the above step is revised, the rotary mold is sequentially turned into a diameter of a forming surface corresponding to the inner peripheral surface of the body wall. For manufacturing sheet metal poly V-groove pulleys, characterized by replacing with small rotary molds . 2. A sheet metal material in which a cylindrical body wall is integrally provided on an outer periphery of a disk-shaped substrate portion, and a surface of the substrate portion and an inner peripheral surface of the body wall are connected via a curved surface. 2. The method for manufacturing a sheet metal poly-V groove pulley according to claim 1, wherein each time the step of forming the poly-V groove is changed, the rotary mold having a curved forming surface corresponding to the curved surface is sequentially rotated by the rotating die. A method of manufacturing a sheet metal poly-V groove pulley which is replaced with a rotary mold having a large radius of curvature of a curved molding surface.