JPH0119984B2 - - Google Patents

Description

[Detailed Description of the Invention] [Object of the Invention] (Industrial Application Field) The present invention relates to a method for manufacturing thin, large-diameter gears by press-forming thin steel plates, and the present invention relates to a method for manufacturing thin, large-diameter gears for use in torque converters of automobiles. This is a widely used method for manufacturing drive plates.

(Prior Art) As shown in FIG. 15, a conventional drive plate according to the present invention is composed of a ring-shaped thick part 16 and a disc-shaped plate part 17, and the plate part 17 has a thickness of 2.0 to 2.0 mm. It is formed by press processing from a 3.0 mm plate material, and the thick part 16 has a rectangular cross section (thickness 9~
10 x width 17~20 mm) is coiled in a spiral shape, cut and welded each coil to form a ring shape, and after deburring the joint, a tooth shape is formed on the outer circumferential surface using a hobbing machine, etc. molded. In this way, the thin plate part and the thick part having teeth are molded separately, and the thin plate part and the thick tooth part are welded and joined as shown in 18 to be integrated.

(Problems to be Solved by the Invention) However, the method for manufacturing the drive plate requires finishing and welding of the joints in order to integrate the separate thin plate part 17 and the thick toothed part 16. This welding process tends to cause distortion, and insufficient strength due to poor welding.

In addition, in order to improve material yield for thick-walled tooth-shaped parts, rods with a rectangular cross section are coiled and formed into a ring shape, but this requires many processing steps, which increases the overall processing cost when combined with the welding process mentioned above. There is a problem.

An object of the present invention is to provide a method for manufacturing a drive plate that does not require any welding.

[Structure of the invention]

(Means for solving the problem) The technical measures taken to solve the above technical problem were as follows: (1) using a thin disc of the drive plate, punching out the disc in the blanking process; ) In the drawing process, the outer periphery of the disk is bent to form a cup shape. (3) In the V-groove forming process, a part of the cup-shaped side wall part is formed inward to form a V-groove of approximately 60°, ( 4) The side wall portion left in the necking forming process is bent inward by approximately 60 degrees, and the end portion of the side wall portion is bent inward to make the entire side wall shaped like a bellows. (5) In the tight bending process, the bellows-shaped sidewall (6) In the plate forming process, the end of the quadruple-bent side wall part is bent inside the thickened part in the plate forming process. At the same time, the plate part is formed into a predetermined shape, (7) mounting holes etc. are drilled in the plate part in the pilot hole punching process, and (8) in the rolling process, the four-layered thick part is fitted with a gear rolling machine. The teeth are rolled and formed by plastic working.

Through the above steps, a drive plate having teeth in the thicker portion is formed from a single thin plate.

(Operation) The technical means operates as follows. In other words, the necessary parts of the drive plate are overlapped on the outer periphery to thicken the drive plate to a predetermined dimension, and the tooth profile is formed by plastic deformation in a gear rolling machine.The thin plate part and the thick tooth profile part cannot be formed integrally. This eliminates the need for welding.

(Example) Specific examples will be described below.

1 is a disc material punched from the same thickness (2.0 to 3.0 mm) as the thin plate portion of the drive plate.

Next, in a drawing process, the outer periphery is bent to form a cup shape 2, and the mold is a drawing punch 3.
a, a die cutter 3b, a wrinkle presser 3c, and a die 3d.

Next, in the V-groove forming step shown in 4, a part of the side wall is rotation-molded inward into a V-groove shape, and the rotating blank holder 5a and the shaft eccentric to the blank holder by more than the depth of the V-groove are used. It is molded by a mold consisting of an eccentric inner roller 5b that rotates and is movable in the axial direction and the axis-perpendicular direction, and a molding roller 5c that rotates and is movable in the axis-perpendicular direction. After forming the V-groove, it moves toward the center of the blank and further toward the opposite direction of the blank holder to be removed from the molded product.

Next, in the netting process shown in 6, the side wall portion 4a remaining from the V-groove forming process is rotationally molded inward, and the rotating blank holder 7a, eccentric inner roller 7b, and movable in the axial direction and the axis-perpendicular direction A mold formed by a forming roller 7c forms a tapered part 6a facing the inner diameter and a straight end part 6.
b, and the entire side wall portion is molded into a bellows shape.

Next, as shown in 8, the bellows-shaped side wall part is tightly folded in a molding process to form a thick part in four layers as shown in 8a, and a guide die 9 is used.
a, a mold with a close bending punch 9b and a knockout 9c. At this time, the terminal portion 6b is formed into a tapered shape 8b toward the bottom.

Next, as shown in 10, in a plate forming process, the terminal 8b is closely molded inside the thick wall part as shown in 10b, and the plate part 8c is formed into a predetermined mounting shape 10a, using a forming die 11a and a forming punch. 11b and a guide die 11c.

Next, as shown at 12, holes 12a and 12b for mounting and weight reduction are formed in the plate portion 10a using a punching die (not shown).

Next, a toothed portion 13a is formed on the outer periphery of the drive plate material 12 whose outer periphery has four layers of wall thickness using a gear rolling machine.
The tooth portion 13a is formed by plastic deformation using a gear rolling device consisting of a lower blank holder 14d and a lower blank holder 14d.

Using the above manufacturing method, a module is made from a thin plate 1 of 2.0 to 3.0 mm with a thickness of 8 to 10 mm at the outer periphery.
A drive plate 13 having teeth of 2.0 to 3.0 is formed.

〔Effect of the invention〕

The present invention has the following unique effects. That is,
There is also a drive plate in which the outer periphery of thin steel is bent into three pieces, but compared to this, it is possible to form teeth with a larger tooth width relative to the material plate thickness, and the flow of material in the tooth width direction is well balanced. Good quality gears with no internal cavities can be formed.

[Brief explanation of drawings]

Figures 1 to 14 show each process of this embodiment, with Figure 1 being a partially omitted cross-sectional view of a disc material, Figure 2 being a cup-shaped cross-sectional view, and Figure 3 being a cross-sectional view of a cup-shaped material. The figure is a diagram of the drawing process, Figure 4 is a cross-sectional view of V-groove forming, Figure 5 is a cross-sectional view of V-groove forming, Figure 6 is a cross-sectional view of netting, and Figure 7 is a cross-sectional view of the netting process. Fig. 8 is a cross-sectional view of the outer periphery of the disk thickened by contact molding, Fig. 9 is a contact molding process diagram, and Fig. 10 is a side wall end portion and a plate portion formed into a predetermined shape. FIG. 11 is a cross-sectional view of the plate molding process, FIG. 12 is a cross-sectional view of the drive plate material, and FIG. 13 is a partially omitted cross-section of the drive plate formed by this manufacturing process. FIG. 14 is a diagram showing a tooth forming process using a gear rolling device, and FIG. 15 is a cross-sectional view of a main part of a conventional drive plate with some parts omitted. 1...disk, 2...cup shape, 12...drive plate material, 13...drive plate.

Claims (1)

[Scope of Claims] 1. A method for manufacturing a drive plate for an automobile, which is a large-diameter gear with a thick wall at the periphery and a thin wall at the center, by press working, rotary molding, and rolling process, comprising: (1) blanking; In the process, a 2.0 to 3.0 mm disc is punched out. (2) In the drawing process, the outer periphery of the disc is bent to form a cup shape. (3) In the V-groove forming process, the side wall near the bottom of the cup shape is formed. (4) In a netting step, the side wall portion on the end side of the V-groove formed portion bent inward is bent inward to make the entire side wall portion into a bellows shape; (5) In the close bending step, the bellows-shaped side wall portion is brought into close contact with the bottom to form a quadruple layer, thereby thickening the outer periphery of the disk; (6) In the plate forming step, the end of the quadruple bent side wall portion is bent inward. At the same time, the plate part is formed into a predetermined mounting shape, (7) the drive plate material formed into the plate part is formed in the hole punching process, and (8) gear rolling is performed on the outer periphery of the drive plate material in the rolling process. A method of manufacturing a drive plate by forming teeth using a device.