JP6958174B2 - Manufacturing method of toothed pulley - Google Patents

Description

The present invention relates to a method for manufacturing a toothed pulley in which a tooth portion is formed by drawing.

As a method for manufacturing a toothed pulley, a single disk-shaped metal plate is subjected to a first drawing process, and a substantially cylindrical rim portion and an axially first end portion of the rim portion to the inside in the radial direction. There are various manufacturing methods in which a first molded body having an extending disc portion is manufactured, and the rim portion of the first molded body is subjected to a second drawing process to form a tooth portion to obtain a toothed pulley. It has been proposed (see, for example, Patent Document 1).

Normally, a steel plate or an aluminum plate having excellent drawability is used as the metal plate, and the tooth portion is formed on the rim portion of the first molded body by a single second drawing process using a punch and a die. Is going.

Jitsufuku No. 5-4898 Gazette

By the way, in the method for manufacturing a toothed pulley, when the second drawing process is performed on the first molded body, the rim portion and the disk portion of the toothed pulley are caused by friction between the rim portion and the die of the first molded body. There is a problem that a tensile force acts on the continuous portion with and the continuous portion causes sagging in the continuous portion, or the continuous portion or its vicinity is broken. Further, due to the friction between the rim portion and the die of the first molded body, the outer peripheral surface of the rim portion is pulled by the die, the rim portion becomes longer, and the burr that protrudes in the axial direction from the outer peripheral surface of the free end portion of the rim portion. There is a problem that is formed.

In the invention described in Patent Document 1, in order to solve the former problem, a receiving surface for receiving the end portion of the rim portion is formed on the punch used in the second drawing process to regulate the movement of the rim portion and cause sagging. It is configured to prevent the occurrence.

However, even in the invention described in Patent Document 1, the occurrence of sagging cannot be completely prevented and the latter problem cannot be solved. Therefore, in the end, as a post-process of the second drawing process, a finishing process such as a cutting process is performed. It is necessary to provide.

Further, as the material metal plate of the toothed pulley, a steel plate or an aluminum plate suitable for deep drawing is usually used, but the stainless steel plate is excellent in strength and rigidity and durability, but is work-hardened. However, if this is not removed or properly controlled, there is a problem that the continuous portion breaks during the second drawing process, so that the actual situation is that it has not been adopted.

An object of the present invention is to provide a method for manufacturing a toothed pulley, which can expand the degree of freedom in selecting a material and can sufficiently secure dimensional accuracy while improving the efficiency of finishing work.

The present invention includes the following inventions.
(1) A method for manufacturing a toothed pulley having a substantially cylindrical rim portion having a tooth portion formed on an outer peripheral portion and a disc portion extending inward in the radial direction from the first axial end portion of the rim portion. And
A single disk-shaped metal plate made of austinite-based stainless steel plate is subjected to a first drawing process from a substantially cylindrical first rim portion and an axially first end portion of the first rim portion. Molding into a first molded body having the disk portion extending inward in the radial direction, and
To form a tooth portion on the first rim portion of the first molded body by a second drawing process,
The second rim portion of the second molded body and the said The radius R2 of the arc of the portion connected to the disk portion matches the radius R2 of the arc of the portion connected to the rim portion and the disk portion of the toothed pulley, which is smaller than that, and the second The second molded body is embedded and processed so that the burr portion protruding from each tooth portion in the axial direction at the second end portion of the molded body is flatly crushed.
With
At the time of the stationary processing, the ratio R / R2 of the radius R to the radius R2 is set to 25% to 50%, and at the same time,
In the punch used for the embedding process, the tip of each ridge of the punch and the inner peripheral surface of the tip of each tooth have a clearance similar to the plate thickness of the tooth tip of the tooth. Manufacturing method of toothed pulley.

In this manufacturing method, the radius R2 of the continuous portion of the second molded body is matched with the radius R of the continuous portion of the toothed pulley, which is smaller than that, by performing the stationary processing on the second molded body. The burr portion formed at the second end of the second rim portion is flatly crushed to finish the toothed pulley, so that the efficiency of the finishing work is higher than that of finishing by cutting. Sufficient dimensional accuracy can be ensured while improving the quality. Moreover, by adjusting the radius R2 of the continuous portion of the second molded body so as to match the radius R of the continuous portion of the toothed pulley, which is smaller than that, the continuous portion of the toothed pulley is connected. Since the radius R of the installation portion can be set small to reduce the radius due to sagging of the final product, the effective tooth profile portion can be made large. Further, since the radius R2 of the continuous portion of the second molded body can be set large, the tensile load during the second drawing process can be reduced to form the tooth portion without difficulty with respect to the rim portion of the first molded body. Can be done. Further, since the ratio R / R2 of the radius R to the radius R2 is set to 25% or more at the time of the embedding process, there is a risk that the tooth bottom portion of the end face will be over-compressed and the mold will be damaged. It can be avoided. Furthermore, since the R / R2 is set to 50% or less, the amount of deformation of the continuous portion during drawing of the second molded body can be reduced, and the tensile load acting on the continuous portion can be reduced. Further, in the punch used for the embedding process, the clearance between the tip of each ridge of the punch and the inner peripheral surface of the tip of each tooth has the same clearance as the thickness of the tooth tip of the tooth. Therefore, it is possible to reduce the molding load at the time of stationary processing. In this way, since the moldability of the continuous portion of the second molded body, which has the strictest molding conditions, can be improved, an austinite-based stainless steel sheet, which has been considered difficult to mold due to problems associated with work hardening, is used. However, it is possible to manufacture a toothed pulley without difficulty.

(2) the second rim portion of the second molded body joint portion of the arc of the radius R2 of the disk portion, than the arc of the radius R1 of the joint portion of said disc portion and the first rim portion The method for manufacturing a toothed pulley according to (1) above, which is set to be small. In this case, since the radius R1 of the arc of the continuous portion of the first molded body can be set large, the amount of deformation of the plate in the continuous portion of the first molded body is reduced during the first drawing process. 1 The molded body can be molded without difficulty.

( 3 ) The above (1) provided with a solidification treatment for recovering work hardening after one or more types of processing selected from the first drawing process, the second drawing process, and the stationary processing. Alternatively, the method for manufacturing a toothed pulley according to (2). With such a configuration, it is possible to more effectively prevent breakage of the continuous portion due to work hardening.

( 4 ) One or more types of processing selected from the first drawing process, the second drawing process, and the stationary processing are performed at a temperature of 80 ° C. or higher and 500 ° C. or lower, or 800 ° C. or higher and 1100 ° C. The method for manufacturing a toothed pulley according to any one of (1) to (3 ) above, which is applied in the following hot period. With such a configuration, since the molding load increases due to work hardening, it is possible to more effectively prevent breakage of the continuous portion.

( 5 ) When the second molded body is installed, the second end portion of the second molded body is installed on the receiving surface by turning the second molded body upside down from the time of the second drawing process. The method for manufacturing a toothed pulley according to any one of (1) to (4 ) above, wherein the second molded body is placed in this state. In this embedding process , the second molded body is set up using punches and dies suitable for the final product, but in the second drawing process , the second formed body is set upside down, so it is set up. The second rim portion can be compressed in the axial direction as a whole, and the dimensional accuracy of the rim portion can be easily improved. In addition, the tooth profile of the die that matches the final product can be installed while guiding the outer peripheral portion of the second molded body, so that the second molded body can be pulled in in the loading direction while ensuring shape accuracy. The effect of reducing the stationary load can be obtained.

( 6 ) The toothed pulley according to any one of (1) to (5 ) above, wherein in the second drawing process, the tooth portion is gradually drawn to the required dimensions using a plurality of sets of punches and dies. Production method. With this configuration, even a metal material such as an austinite-based stainless steel sheet that is easily work-hardened can be formed with even more effortlessly.

( 7 ) The tooth attachment according to any one of (1) to (6 ) above, in which the tooth portion is formed by using a punch configured so as not to contact the tooth bottom portion of the tooth portion in the second drawing process. How to manufacture the pulley. With such a configuration, it is possible to prevent excessive tension from acting on the continuous portion and its vicinity during the second drawing process, and effectively prevent breakage of the continuous portion and its vicinity.

According to the method for manufacturing a toothed pulley according to the present invention, the toothed pulley is finished by performing a stationary process on the second molded body, so that the efficiency of the finishing work can be improved as compared with the case where the toothed pulley is finished by cutting. Sufficient dimensional accuracy can be ensured while trying. Moreover, since the radius R of the continuous portion of the toothed pulley can be set small to reduce the radius due to sagging of the final product, the effective tooth profile portion can be made large. Further, since the radius R2 of the continuous portion of the second molded body can be set large, the tensile load during the second drawing process can be reduced to form the tooth portion without difficulty with respect to the rim portion of the first molded body. Can be done. Therefore, even if an austinite-based stainless steel plate, which has been conventionally considered to be difficult to mold, is used, a toothed pulley can be manufactured without difficulty.

FIG. 1 is a perspective view of a toothed pulley assembly. FIG. 2 is an exploded perspective view of the toothed pulley assembly. FIG. 3 is a cross-sectional view taken along the line III-III of FIG. FIG. 4A is a front view of the toothed pulley. FIG. 4B is a sectional view taken along line IV-IV of FIG. 4A. FIG. 5A is a perspective view of the metal plate 2A. FIG. 5B is a perspective view of the metal plate 2B. FIG. 5C is a perspective view of the first molded product. FIG. 6A is an explanatory diagram of the first drawing step. FIG. 6B is an explanatory diagram of the first drawing step. FIG. 6C is an explanatory diagram of the first drawing step. FIG. 6D is an explanatory diagram of the first drawing step. FIG. 7A is an explanatory diagram of the second drawing step. FIG. 7B is an explanatory diagram of the second drawing step. FIG. 7C is an explanatory diagram of the second drawing step. FIG. 7D is an explanatory diagram of the second drawing step. FIG. 8A is an explanatory diagram of a punch and a die used in the second drawing step. FIG. 8B is an explanatory diagram of a punch and a die used in the second drawing step. FIG. 8C is an explanatory diagram of a punch and a die used in the second drawing step. FIG. 9A is an explanatory diagram of the installation process. FIG. 9B is an explanatory diagram of the installation process. FIG. 9C is an explanatory diagram of the installation process. FIG. 10 is a cross-sectional view of a main part of the third die, the third punch, and the rim portion 10 installed therein. FIG. 11A is a vertical cross-sectional view of a main part of the second molded body after the second drawing step. FIG. 11B is a vertical cross-sectional view of a main part of the toothed pulley after the installation process.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
First, the configuration of the toothed pulley assembly including the toothed pulley will be described.
As shown in FIGS. 1 to 3, the toothed pulley assembly 1 includes a toothed pulley 2 and a first flange member 3 and a second flange member 4 fixed to both sides thereof by brazing or the like. .. The toothed pulley 2 can be used as a component for power transmission of any device, such as for power transmission in a motorcycle or for power transmission to a camshaft of an automobile engine.

As shown in FIGS. 2, 4, 4A, and 4B, the toothed pulley 2 has a substantially cylindrical rim portion 11 having a tooth portion 10 formed on an outer peripheral portion, and an axial first end of the rim portion 11. It has a disk portion 12 extending inward in the radial direction from the portion, and is manufactured by a manufacturing method described later using a metal plate.

A substantially flat annular mounting portion 13 is formed in the central portion of the disk portion 12, an annular step portion 14 is formed on the outer peripheral side of the mounting portion 13, and the mounting portion 13 is connected to the rim portion 11 via the step portion 14. It is arranged in the middle of the axial direction of the above, and a central opening 15 is formed in the central portion of the mounting portion 13. However, the shape of the disc portion 12 can be arbitrarily set according to the configuration of the object to be assembled to which the toothed pulley 2 is assembled.

As the metal material constituting the toothed pulley 2, any metal material can be adopted as long as it can be deeply drawn. For example, iron-based metals such as stainless steel, soft iron and steel, and non-iron metals such as aluminum alloys are used. be able to. In particular, in the present invention, the toothed pulley 2 can be manufactured reasonably efficiently and accurately while using austinite-based stainless steel, which has been conventionally considered to be difficult to mold due to work hardening. Further, the plate thickness and outer diameter of the toothed pulley 2, the number and shape of the tooth portions 10 and the like can be arbitrarily set.

The first flange member 3 and the second flange member 4 are manufactured by press-molding a metal plate made of an iron-based metal such as stainless steel, soft iron or steel, or a non-iron metal such as an aluminum alloy plate.

An annular flange portions 3a and 4a having a diameter slightly larger than that of the rim portion 11 are formed on the outer peripheral portions of the first flange member 3 and the second flange member 4, respectively. The toothed belt 5 to be wound is restricted from moving in the axial direction so that the toothed belt 5 does not fall off from the toothed pulley 2.

A polymerization portion 3b to be overlapped with the disk portion 12 is formed on the inner peripheral portion of the first flange member 3, and a polymerization portion 4b to be overlapped with the disk portion 12 is formed on the inner peripheral portion of the second flange member 4. There is. A plurality of fixing holes 6 are formed in a penetrating shape at intervals in the circumferential direction in the overlapping portion of the mounting portion 13, the overlapping portion 3b, and the overlapping portion 4b, and a fixing tool such as a bolt is attached to the plurality of fixing holes 6. By inserting it, the toothed pulley assembly 1 can be assembled to an object to be assembled such as a wheel.

However, as the first flange member 3 and the second flange member 4, any configuration can be adopted according to the configuration of the object to which the toothed pulley 2 is assembled.

Next, a method of manufacturing the toothed pulley 2 will be described.
The method for manufacturing the toothed pulley 2 includes a first punching step, a second punching step, a first drawing step, a second drawing step, and an embedding step.

In the first punching step, as shown in FIG. 5A, the material metal plate is punched into a disk shape, and the positioning hole 20 is punched in the central portion thereof to manufacture a substantially flat metal plate 2A.

In the second punching step, as shown in FIG. 5B, the metal plate 2A is press-processed to form an annular step portion 14 in the middle portion in the radial direction, and a fixing hole 6 and a central opening are formed in the central portion of the metal plate 2A. A metal plate 2B having a flat plate annular outer peripheral portion 21 and a disc portion 12 arranged inside the outer peripheral portion 21 is manufactured by punching out the portion 15.

However, in the first punching step, the material metal plate is punched into a disk shape, and the step portion 14 is formed and the fixing hole 6 and the central opening 15 are punched at the same time, so that the second punching step may be omitted. can. Further, the fixing hole 6 and the central opening 15 can be punched out at an arbitrary timing, for example, after the embedding step.

In the first drawing step, a cylindrical first rim portion 11C is drawn on the outer peripheral portion 21 of the metal plate 2B by using the first die 30 and the first punch 31 having the configurations shown in FIGS. 6A to 6D. Molded by. In FIGS. 6A to 6D, the first die 30 and the first pressing plate 33, the metal plate 2B, and the first molded body 2C are represented by end views on the cut surface, and have a configuration behind the cut surface. The description is omitted.

The first die 30 forms a circular opening 30a having a size suitable for the outer diameter of the first rim portion 11C at the center of the metal plate, and goes downward to the lower part of the inner peripheral surface of the opening 30a. Therefore, the guide surface 30b having a large diameter is formed.

The first punch 31 is made of a disk-shaped metal plate having a size suitable for the inner diameter of the first rim portion 11C, and has an annular protrusion 31a having a size suitable for the inner space of the first rim portion 11C on the outer peripheral portion. The first radius 31b formed of an annular arc surface is formed on the outer peripheral edge of the upper end portion of the annular protrusion 31a, and the first positioning member 32 is provided in a central portion so as to project upward.

In the first drawing step, first, as shown in FIG. 6A, the metal plate 2B is externally fitted to the first positioning member 32, and the metal plate 2B is positioned and placed on the first punch 31.

Next, as shown in FIG. 6B, the first presser plate 33 is lowered relative to the first punch 31, and the disk portion 12 of the metal plate 2B is placed between the first punch 31 and the first presser plate 33. Holds almost the entire.

Next, as shown in FIG. 6C, the first die 30 is lowered relative to the first punch 31, and the outer peripheral portion 21 of the metal plate 2B is drawn between the first die 30 and the first punch 31. Then, a substantially cylindrical first rim portion 11C is formed, and as shown in FIG. 5C, the first rim portion 11C and the disk portion 12 extending inward in the radial direction from the first end portion in the axial direction are formed. The first molded body 2C to have is manufactured.

Next, as shown in FIG. 6D, the first die 30 and the first pressing plate 33 are moved upward, and then the first knockout member 34 is moved upward to move the first punch 31 to the first molded body 2C. Is extracted to obtain the first molded product 2C.

In the second drawing step, a plurality of tooth portions 10D are drawn on the first rim portion 11C of the first molded body 2C by using the second die 40 and the second punch 41 having the configurations shown in FIGS. 7A to 7D. Molded by. In FIGS. 7A to 7D, the second die 40 and the second pressing plate 43, and the first molded body 2C and the second molded body 2D are represented by end views on the cut surface, and are rearward of the cut surface. The description of the configuration is omitted.

The second die 40 is made of a metal plate having a circular opening 40a, and a plurality of dice 40 projecting inward so as to correspond to the tooth bottom of each tooth portion 10 of the toothed pulley 2 on the inner peripheral portion of the opening 40a. The die side ridge 40b is formed along the height direction of the second die 40, and the protruding length and the width in the circumferential direction of the lower half of the die side ridge 40b are set to the lower side in the lower part of the die side ridge 40b. It is set so that each becomes smaller as it goes to. When the die-side ridge 40b is configured in this way, a conical introduction portion whose opening diameter increases as it goes downward is formed on the inner peripheral surface of the opening 40a, and when the first molded body 2C is drawn. Since the tooth portion 10D is gradually formed into a desired shape, the tooth portion 10D can be processed with high accuracy.

The second punch 41 is made of a substantially disk-shaped metal plate having a size that can be fitted into the second rim portion 11D, and has an annular protrusion 41a having a size that fits the inner space of the second rim portion 11D on the outer peripheral portion. A second radius 41b composed of an annular arc surface is formed on the outer peripheral edge of the upper end portion of the annular protrusion 41a, and the outer peripheral surface corresponds to the tooth tip of each tooth portion 10 of the toothed pulley 2. A plurality of punch-side protrusions 41c projecting toward the direction are formed along the height direction of the second punch 41, and the second positioning member 42 is provided in a central portion so as to project upward.

In the second drawing step, first, as shown in FIG. 7A, the continuous portion 16C between the disc portion 12 and the first rim portion 11C of the first molded body 2C is placed on the upper side, and the first rim portion of the first molded body 2C is placed on the upper side. The annular protrusion 41a of the second punch 41 is fitted inside the 11C, the first molded body 2C is externally fitted to the second positioning member 42 at the center of the second punch 41, and the second punch 41 is the second. 1 The molded body 2C is positioned and set.

Next, as shown in FIG. 7B, the second pressing plate 43 is lowered relative to the second punch 41, and the disc portion of the first molded body 2C is formed between the second punch 41 and the second pressing plate 43. Holds twelve.

Next, as shown in FIG. 7C, the second die 40 is lowered relative to the second punch 41, and the die side ridge 40b of the second die 40 and the punch side ridge 41c of the second punch 41 are lowered. Then, a plurality of tooth portions 10D are formed on the first rim portion 11C of the first molded body 2C, and the second rim portion 11D having the plurality of tooth portions 10D and the first end in the axial direction of the second rim portion 11D are formed. A second molded body 2D having a disk portion 12 extending inward in the radial direction from the portion is manufactured.

At this time, in the second rim portion 11D, the second die 40 is attached to the tooth tip of each tooth portion 10D at the second end portion opposite to the continuous portion 16D between the disc portion 12 and the second rim portion 11D. Due to the frictional resistance, a burr portion 17 (see FIG. 11A) protruding outward in the axial direction is formed, and the radius R2 of the arc on the outer peripheral surface of the continuous portion 16D is the continuous portion of the first molded body 2C. It is molded so as to be the same as or slightly smaller than the radius R1 of the arc on the outer peripheral surface of 16C.

Next, as shown in FIG. 7D, the second die 40 and the second pressing member 43 are moved upward, and then the second knockout member 44 is moved upward to move the second punch 41 to the second molded body 2D. Is extracted to obtain the second molded product 2D.

In this second drawing step, the tooth portion 10D can be formed to have the required dimensions with one set of the second die 40 and the second punch 41, but a plurality of sets of the second die and the second punch are combined. It is also possible to provide and form the tooth portion 10D step by step so as to have the required dimensions. Specifically, when the tooth portion 10D is formed to the required dimensions step by step by three drawing processes, the protruding heights of the die-side ridge and the punch-side ridge are as shown in FIGS. 8A to 8C. A second die 45 having a die-side ridge 45b and a second punch 46 having a punch-side ridge 46c, and a second die 47 having a die-side ridge 47b and a punch-side ridge Using the second punch 48 having 48c, the second die 40 having the die-side ridge 40b, and the second punch 41 having the punch-side ridge 41c, stepwise like the teeth 10A, 10B, 10D. The tooth portion 10D can be formed. However, although the number of sets of the second die and the second punch can be arbitrarily set, in the final stage, drawing is performed using the second die 40 and the second punch 41.

By forming the tooth portion 10D stepwise to the required dimensions in this way, the surface pressure during drawing of the second molded body 2D can be reduced, work hardening can be suppressed, and drawing can be performed with a low load. The life of the two dies 40, 45, 47 and the second punches 41, 46, 48 can be improved.

Further, as shown in FIG. 8C, for example, the second rim portion 11D so as not to come into contact with the second rim portion 11D except for the tip side portion of the punch side ridge 41c in the height direction of the second punch 41. It may be configured so as not to come into contact with the second punch 41 within a range of 30% or more and 80% or less, preferably 40% or more and 60% or less of the inner peripheral length. Further, the clearance C1 between the second punch 41 and the second die 40 in the tooth bottom portion of the tooth portion 10D of the second molded body 2D can be arbitrarily set, but is the second of the second molded body 2D. The plate thickness t of the 2 rim portion 11D may be set to 1.5 times or more, or 1.5 times or more and 3 times or less the plate thickness t. With this configuration, the surface pressure during drawing of the second molded body 2D can be reduced, work hardening can be suppressed, and drawing can be performed with a low load, so that the life of the second die 40 and the second punch 41 can be reduced. Can be improved.

Between both ends of the tooth portion 10D of the second molded body 2D in the circumferential direction and the corner portion of the inner end of the fitting recess of the second die 40 that is externally fitted to the tooth portion 10 of the second molded body 2D. A clearance C2 is formed in the tooth.

In the embedding step, the third die 50, the third punch 53, and the underlay plate 54 having the configurations shown in FIGS. 9A to 9C are used to install the third die 50 with respect to the second rim portion 11D of the second molded body 2D. Perform inset processing. In FIGS. 9A to 9C, the third die 50 and the third punch 53, the second molded body 2D, and the toothed pulley 2 are represented by end views on the cut surface, and have a configuration behind the cut surface. The description is omitted.

The third die 50 is divided into an upper die 51 and a lower die 52. The upper die 51 is made of a metal plate having a circular opening 51a, and is configured so that the inner peripheral portion of the opening 51a can be fitted to the outer surface of the third punch 53 with substantially no gap, and each tooth portion of the toothed pulley 2 is formed. The upper die side ridge 51b is formed corresponding to the tooth bottom of 10, and the receiving surface 51c capable of contacting the upper surface of the rim portion 11 of the toothed pulley 2 is formed on the lower surface of the upper die 51. The lower die 52 is made of a metal plate having a circular opening 52a, and can be fitted to the inner peripheral portion of the opening 52a on the outer surface of the toothed pulley 2 without any gap. The lower die side ridge 52b is formed corresponding to the tooth bottom, and the protruding length and the width in the circumferential direction of the lower half of the lower die side ridge 52b are set to become smaller toward the lower side. Is.

The third punch 53 is made of a substantially disk-shaped metal plate having a size that can be fitted into the rim portion 11, and has an annular protrusion 53a having a size that fits the inner space of the rim portion 11 on the outer peripheral portion. A third radius 53b composed of an annular arc surface is formed on the outer peripheral edge of the lower end portion of the annular protrusion 53a, and the outer peripheral surface corresponds to the tooth tip of each tooth portion 10 of the toothed pulley 2 and projects outward. A plurality of punch-side protrusions 53c are formed along the height direction of the third punch 53. As shown in FIG. 10, a clearance C3 having the same thickness as the tooth tip is formed between the tip of the punch-side ridge 53c and the inner surface of the tip of the tooth 10 of the toothed pulley 2 and is installed. It is configured so that the forming load at the time of indentation can be reduced, and the inner peripheral surface of the rim portion 11 of the toothed pulley 2 is fitted to the outer peripheral surface of the third punch 53 with almost no gap in the portion other than the clearance C3. It is configured in.

The lower support plate 54 is made of a substantially disk-shaped metal plate having a size that can be fitted into the lower die 52 without any gap, and has a groove that can be fitted into the lower die side protrusion 52b of the lower die 52 on the outer peripheral surface. The 54a is formed so as to correspond to the ridge 52b on the lower die side, and the outer peripheral portion of the upper surface is formed with a receiving surface 54b that can receive the outer peripheral portion of the disc portion 12 of the second molded body 2D from the lower side.

In the embedding step, first, as shown in FIG. 9A, the second molded body 2D is externally fitted to the positioning pin 55 provided on the lower receiving plate 54 and positioned by turning it upside down from the case of the second drawing step. At the same time, the continuous portion 16 of the disc portion 12 and the second rim portion 11D is placed on the receiving surface 54b of the lower receiving plate 54 and positioned and set on the lower receiving plate 54.

Next, as shown in FIG. 9B, the third punch 53 is lowered relative to the lower receiving plate 54, and the disc portion 12 of the second molded body 2D is placed between the third punch 53 and the lower receiving plate 54. Hold.

Next, as shown in FIG. 9C, the third die 50 is lowered relative to the third punch 53, and the second rim portion 11D is placed between the third die 50 and the third punch 53 as the third die. The second rim is located between the receiving surfaces 54b and 51c while ensuring the accuracy of the rim portion 11 by compressing while guiding on the inner surface of the 50 and sticking it to the lower die side protrusion 52b of the third die 50. The toothed pulley 2 is obtained by performing a stationary process on the portion 11D. Specifically, between the third die 50 and the third punch 53, the outer peripheral surface of the second rim portion 11D of the second molded body 2D is finished to a size suitable for the outer surface shape of the rim portion 11 of the toothed pulley 2. At the same time, between the receiving surfaces 54b and 51c, as shown in FIGS. 11A and 11B, the radius R2 of the arc of the continuous portion 16D between the second rim portion 11D and the disc portion 12 of the second molded body 2D is set. It is installed so as to match the radius R of the continuous portion 16 of the disc portion 12 and the rim portion 11 of the toothed pulley 2, which is smaller than the size, and further, from each tooth portion 10D at the second end portion of the second molded body 2D. The burr portion 17 protruding in the axial direction is crushed flat.

Here, if the ratio R / R2 of the radius R to the radius R2 is set to 25% or more, it is possible to avoid the risk that the tooth bottom portion of the end face will be overcompressed and the mold will be damaged, and it will be 50% or less. If it is set, the amount of deformation of the continuous portion 16D during drawing of the second molded body 2D can be reduced, and the tensile load acting on the continuous portion 16D can be reduced, so that it may be 25% to 50%.

In this method of manufacturing the toothed pulley 2, the joint portion 16C of the first rim portion 11C and the first disk portion 12 is formed by the first drawing process, and the radius R1 of the arc is the second in the second molded body 2D. Since it can be formed so as to be larger than the radius R2 of the arc of the joint portion 16D of the rim portion 11D and the disc portion 12, the metal plate is deformed in the continuous portion 16C of the first molded body 2C during the first drawing process. The first molded body 2C can be formed without difficulty by reducing the amount. Further, the radius R2 of the continuous portion 16D of the second molded body 2D is made larger than the radius R of the arc of the continuous portion 16 between the rim portion 11 and the disc portion 12 in the toothed pulley 2 as the final product. Since it can be molded, the tensile load during the second drawing process can be reduced, and the tooth portion 10D can be formed without difficulty with respect to the rim portion 11C of the first molded body 2C. As described above, since the moldability of the continuous portion 16D of the second molded body 2D, which has the strictest molding conditions, can be improved, the degree of freedom of selection for the material of the toothed pulley 2 can be expanded. A toothed pulley can be manufactured without difficulty even by using an austenite-based stainless steel plate that has been considered. Further, by performing the embedding process on the second molded body 2D, the radius R2 of the continuous portion 16D of the second molded body 2D is reduced to the radius R2 of the continuous portion 16 of the toothed pulley 2 which is smaller than that. The burr portion 17 formed at the second end of the second rim portion 11D is flatly crushed to finish the toothed pulley 2, so that the toothed pulley 2 is finished as compared with the case of finishing by cutting. , Sufficient dimensional accuracy can be ensured while improving the efficiency of finishing work. Moreover, the radius R2 of the continuous portion 16D of the second molded body 2D is adjusted so as to match the radius R2 of the continuous portion 16 of the toothed pulley 2 which is smaller than that, and the radius due to the sagging of the final product is adjusted. Since it can be made smaller, the effective tooth profile can be made larger. In addition, since the second molded body 2D is installed by turning the second molded body 2D upside down, it is possible to improve the tooth profile accuracy and the strength by making the plate thickness uniform.

After one or more types of processing selected from the first drawing process, the second drawing process (when the second drawing process is performed in stages, the drawing process in each stage) and the stationary processing. It is also possible to provide a solidification treatment for recovering work hardening. When the toothed pulley 2 is made of austinite-based stainless steel or heat-resistant steel, as a solution treatment, the object to be treated is heated to a high temperature of 1000 ° C. or higher to dissolve carbides and the like. , Will be quenched in a gas (preferably hydrogen) atmosphere.

In addition, one type or two or more types of processing selected from the first drawing process, the second drawing process (when the second drawing process is performed in stages, the drawing process in each stage) and the stationary processing are performed. It is also preferable to apply it in a warm temperature of 80 ° C. or higher and 500 ° C. or lower, or in a hot temperature of 800 ° C. or higher and 1100 ° C. or lower. Specifically, one or more selected from the metal plate 2B, the first molded body 2C, and the second molded body 2D are heated to a temperature equal to or higher than the recrystallization temperature of the metal material constituting the toothed pulley 2. The necessary processing will be performed in this state.

When the solution treatment or hot processing is performed in this way, it is possible to more effectively prevent breakage of the continuous portion 16 due to work hardening, so that a metal material that is easily work hardened, for example, austinite stainless steel It is suitable for molding a toothed pulley 2 using a metal plate made of a material.

Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and it goes without saying that the configuration can be changed without departing from the gist of the present invention.

1: Toothed pulley assembly 2: Toothed pulley 3: First flange member 3a: Flange part 3b: Overlaid part 4: Second flange member 4a: Flange part 4b: Overlaid part 5: Toothed belt 6: Fixing hole 10 : Tooth part 11: Rim part 12: Disc part 13: Mounting part 14: Step part 15: Central opening 16: Continuous part 17: Burr part

2A: Metal plate 20: Positioning hole

2B: Metal plate 21: Outer circumference

2C: 1st molded body 11C: Rim portion 16C: Continuous portion 30: 1st die 30a: Opening 30b: Guide surface 31: 1st punch 31a: Circular protrusion 31b: 1st radius 32: 1st positioning member 33 : 1st presser plate 34: 1st knockout member

2D: Second molded body 10D: Tooth portion 11D: Rim portion 16D: Continuous portion 40: Second die 40a: Opening 40b: Die side protrusion 41: Second punch 41a: Circular protrusion 41b: Second radius 41c : Punch side ridge 42: Second positioning member 43: Second pressing plate 44: Second knockout member 10A: Tooth portion 45: Second die 45b: Die side ridge 46: Second punch 46c: Punch side ridge 10B : Tooth 47: Second die 47b: Die side ridge 48: Second punch 48c: Punch side ridge

50: Third die 51: Upper die 51a: Opening 51b: Upper die side ridge 51c: Receiving surface 52: Lower die 52a: Opening 52b: Lower die side ridge 53: Third punch 53a: Circular protrusion 53b : 3rd Earl 53c: Punch Side Protrusion 54: Receiving Plate 54a: Groove 54b: Receiving Surface 55: Positioning Pin C1: Clearance C2: Clearance C3: Clearance

Claims (7)

A method for manufacturing a toothed pulley having a substantially cylindrical rim portion having a tooth portion formed on an outer peripheral portion and a disc portion extending inward in the radial direction from the first end portion in the axial direction of the rim portion. ,
A single disk-shaped metal plate made of austinite-based stainless steel plate is subjected to a first drawing process from a substantially cylindrical first rim portion and an axially first end portion of the first rim portion. Molding into a first molded body having the disk portion extending inward in the radial direction, and
To form a tooth portion on the first rim portion of the first molded body by a second drawing process,
The second rim portion of the second molded body and the said The radius R2 of the arc of the portion connected to the disk portion matches the radius R2 of the arc of the portion connected to the rim portion and the disk portion of the toothed pulley, which is smaller than that, and the second The second molded body is embedded and processed so that the burr portion protruding from each tooth portion in the axial direction at the second end portion of the molded body is flatly crushed.
With
At the time of the stationary processing, the ratio R / R2 of the radius R to the radius R2 is set to 25% to 50%, and the ratio R / R2 is set to 25% to 50%.
In the punch used for the embedding process, the tip portion of each ridge of the punch and the inner peripheral surface of the tip portion of each tooth portion have a clearance comparable to the plate thickness of the tooth tip of the tooth portion.
Manufacturing method of toothed pulley.
Claims wherein the second rim portion of the joint portion of the arc of the radius R2 of the disk portion was set to be smaller than the arc of the radius R1 of the joint portion of said disc portion and the first rim portion 1. The method for manufacturing a toothed pulley according to 1. The first or second aspect of claim 1 or 2, further comprising a solidification process for recovering work hardening after one or more types of processing selected from the first drawing process, the second drawing process, and the stationary processing. Manufacturing method of toothed pulley. One or more types of processing selected from the first drawing process, the second drawing process, and the stationary processing are performed at a temperature of 80 ° C. or higher and 500 ° C. or lower, or at 800 ° C. or higher and 1100 ° C. or lower. The method for manufacturing a toothed pulley according to any one of claims 1 to 3, which is applied in between. When the second molded body is installed, the second molded body is turned upside down in the second drawing process, and the second end portion of the second molded body is installed on the receiving surface. The method for manufacturing a toothed pulley according to any one of claims 1 to 4 , wherein the second molded body is placed. The method for manufacturing a toothed pulley according to any one of claims 1 to 5 , wherein in the second drawing process, the tooth portion is gradually drawn to a required size using a plurality of sets of punches and dies. The method for manufacturing a toothed pulley according to any one of claims 1 to 6 , wherein in the second drawing process, the tooth portion is formed by using a punch configured so as not to come into contact with the tooth bottom portion of the tooth portion.

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