US20110034259A1 - Method of making a washer - Google Patents

Method of making a washer Download PDF

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Publication number
US20110034259A1
US20110034259A1 US12/905,364 US90536410A US2011034259A1 US 20110034259 A1 US20110034259 A1 US 20110034259A1 US 90536410 A US90536410 A US 90536410A US 2011034259 A1 US2011034259 A1 US 2011034259A1
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US
United States
Prior art keywords
blank
forging
washer
rough
prototype disc
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.)
Abandoned
Application number
US12/905,364
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English (en)
Inventor
Shi-Chang Lee
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.)
Chun Zu Machinery Ind Co Ltd
Original Assignee
Chun Zu Machinery Ind Co Ltd
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 Chun Zu Machinery Ind Co Ltd filed Critical Chun Zu Machinery Ind Co Ltd
Assigned to CHUN ZU MACHINERY INDUSTRY CO., LTD. reassignment CHUN ZU MACHINERY INDUSTRY CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LEE, SHI-CHANG
Publication of US20110034259A1 publication Critical patent/US20110034259A1/en
Abandoned legal-status Critical Current

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    • 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
    • B21D28/00—Shaping by press-cutting; Perforating
    • B21D28/24—Perforating, i.e. punching holes
    • 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
    • B21D53/20—Making other particular articles rings, e.g. barrel hoops washers, e.g. for sealing

Definitions

  • the invention relates to a manufacturing method, and more particularly to a method of making a washer.
  • a conventional method of making a washer 11 includes the step of directly punching a metal plate 1 having a predetermined thickness in a punching machine to form the washer 11 .
  • burrs form around the edges of the washer 11 , so that a large amount of material is wasted. Further, the mechanical strength of the washer 11 produced from this method is poor. Moreover, even after the burrs are cut, the edges of the washer 11 are still sharp, and can cause injury to the user's fingers. This results in poor product quality.
  • FIG. 2 another conventional method of making a washer 23 involves using forging equipment 21 to cold forge a wire material 22 to form the washer 23 .
  • the forging equipment 21 has a feeder 211 , a clamping tool 212 , a hollow female mold 213 , and a male mold 215 having a punch rod 214 .
  • This conventional method includes the below steps:
  • the clamping tool 212 clamps the wire material 22 that passes through the feeder 211 and sends the same to the female mold 213 .
  • a predetermined length of the wire material 22 extends out of the female mold 213 , so that the wire material 22 is divided into a clamped section 221 located within the feeder 211 , and an exposed section 222 extending out of the female mold 213 .
  • the aforesaid steps may be repeated to repeat the forging fabrication of the washer 23 .
  • steps (a) and (b) involve forging the circular rod-shaped exposed section 222 of the wire material 22 only once to form the circular flat-shaped prototype disc 223 , the rate of deformation of the material is high, which will lead to poor mechanical properties of the washer 232 .
  • the method involves direct punching and cold forging of the wire material 22 while the exposed and clamped sections 222 , 221 are interconnected and while the clamping tool 212 and the feeder 211 clamp the clamped section 221 , the clamping tool 212 and the feeder 211 will absorb the applied force of the punch rod 214 and friction from the clamped section 221 , resulting in gradual abrasion of and damage to the clamping tool 212 and the feeder 211 .
  • the punch rod 214 must simultaneously push the clamped section 221 downward while punching a hole through the exposed section 222 to separate the washer 23 from the clamped section 221 .
  • This step requires a large forging force, which shortens the service lives of the molds 213 , 215 and the clamping tool 212 . Not only is the clamping accuracy affected, the rate of damage is also increased, leading to increased production costs. When the operation of the forging equipment 21 is stopped for repair and replacement, the production rate is lowered, leading to poor production rate.
  • an object of the present invention is to provide a method of making a washer that has good mechanical properties.
  • Another object of the present invention is to provide a method of making a washer that can prolong the service life of forging equipment.
  • a method of making a washer includes the steps of cutting a section of a wire material to form a blank, forging the blank in a first forging unit to form a rough blank that is larger in width and smaller in thickness than the blank, forging the rough blank in a second forging unit to form a prototype disc that is larger in width than the rough blank, and stamping and cutting the prototype disc in a third forging unit to form the washer.
  • FIG. 1 is a fragmentary perspective view of a metal plate used in making a washer according to a conventional method
  • FIG. 2 is a flow diagram, illustrating the steps involved in making a washer using another conventional method
  • FIG. 3 is a flow diagram, illustrating the steps involved in making a washer using a method according to the first preferred embodiment of the present invention
  • FIG. 4 is a flow diagram, illustrating the steps on how a blank gradually forms into the washer
  • FIG. 5 illustrates how a first forging unit forges the blank to form a rough blank
  • FIG. 6 illustrates how a second forging unit forges the rough blank to form a prototype disc
  • FIG. 7 illustrates how a third forging unit forges the prototype disc to form the washer
  • FIG. 8 is a flow diagram, illustrating how a blank gradually forms into a washer using a method according to the second preferred embodiment of the present invention.
  • FIG. 9 illustrates how a trimming device of the second preferred embodiment trims the edges of the blank
  • FIG. 10 illustrates how a first forging unit of the second preferred embodiment forges the blank to form a rough blank
  • FIG. 11 is a flow diagram, illustrating how a blank gradually forms into a washer using a method according to the third preferred embodiment of the present invention.
  • a method of making a washer 5 employs a forging equipment 3 to forge a wire material 4 into a washer 5 .
  • the forging equipment 3 includes first, second, and third forging units 31 , 32 , 33 .
  • Each of the first and second forging units 31 , 32 includes a female mold 312 , 322 having a mold cavity 311 , 321 , and a male mold 314 , 324 having a punch rod 313 , 323 .
  • the third forging unit 33 includes a female mold 332 having a passage hole 331 , and a male mold 334 having a punch rod 333 .
  • the method of making the washer 5 includes the steps below.
  • a wire material 4 is selected according to the required material and size of a finished product, and is coiled to form a roll.
  • the wire material 4 is straightened and fed to the forging equipment 3 .
  • a section of the wire material 4 is cut by using a cutting device (not shown) as it gradually enters the forging equipment 3 to form a cylindrical blank 41 .
  • the thickness of the blank 41 is calculated according to the required size of the washer 5 .
  • the blank 41 is conveyed to the first forging unit 31 by a conveying device (not shown), and is disposed in the mold cavity 311 of the female mold 312 .
  • the male mold 314 is actuated to move toward the female mold 312 , so that the punch rod 313 can punch and make an initial forging of the blank 41 in the mold cavity 311 .
  • the blank 41 is formed into a rough blank 42 that is larger in width and smaller in thickness than the blank 41 .
  • the rough blank 42 has a first wide portion 421 , a second narrow portion 423 , and an intermediate tapered portion 422 between the first wide portion 421 and the second narrow portion 423 .
  • First and second central aligning indentations 424 , 425 are respectively formed in opposite surfaces of the first wide portion 421 and the second narrow portion 423 .
  • the intermediate tapered portion 422 tapers from the first wide portion 421 to the second narrow portion 423 .
  • the first and second central aligning indentations 424 , 425 are provided to facilitate alignment in the next forging process.
  • the male mold 314 is then actuated to move away from the female mold 312 , and the rough blank 42 is ejected from the female mold 312 .
  • the conveying device turns the rough blank 42 upside down and conveys the same to the second forging unit 32 .
  • the rough blank 42 is placed onto the mold cavity 321 with a partial section thereof extending out of the female mold 321 .
  • the male mold 324 is then actuated to move toward the female mold 322 , so that the punch rod 323 can punch and forge the rough blank 42 .
  • the rough blank 42 is formed into a prototype disc 43 that is larger in width and smaller in thickness than the rough blank 42 .
  • the prototype disc 43 has an outer annular portion 431 surrounding a central portion 433 that is thinner than the outer annular portion 431 and that has the first and second central aligning indentations 424 , 425 .
  • the prototype disc 43 has two opposite surfaces both of which are indented to form the central portion 433 . This facilitates the next forging process.
  • the male mold 324 is then actuated to move away from the second female mold 322 , and the prototype disc 43 is ejected from the female mold 322 .
  • the conveying device conveys the prototype disc 43 to the third forging unit 33 , and places the same onto the female mold 332 .
  • the central portion 433 of the prototype disc 43 is aligned with the passage hole 331 .
  • the male mold 334 is then actuated to move toward the female mold 332 , so that the punch rod 333 can stamp through and cut the central portion 433 of the prototype disc 43 .
  • the central portion 433 falls down into the passage hole 331 , and the prototype disc 43 is formed into the washer 5 having a through hole 51 .
  • the shape of the washer 5 in this embodiment is flat and circular.
  • the male mold 334 is actuated to move away from the female mold 332 , and the washer 5 is ejected from the third forging unit 33 and the forging equipment 3 .
  • the aforesaid steps may be repeated to repeat the forging fabrication of the washer 5 .
  • a method of making the washer 5 according to the second preferred embodiment of the present invention is shown to be similar to the first preferred embodiment.
  • the method further includes the step of trimming the blank 41 in a trimming device 34 before the blank 41 is forged in the first forging unit 31 .
  • the trimming device 34 includes a female mold 342 having a mold cavity 341 , and a male mold 344 having a punch rod 343 .
  • the conveying device conveys the blank 41 to the trimming device 34 , and the blank 41 is placed onto the mold cavity 341 of the female mold 342 .
  • the male mold 344 is actuated to move toward the female mold 342 , so that the punch rod 343 can punch and simultaneously trim the blank 41 in the mold cavity 341 .
  • the trimmed blank 41 ′ has a trimmed and rounded corner 411 ′ at one side, and a trimmed non-rounded corner 412 ′ at the other side.
  • the male mold 344 is then actuated to move away from the female mold 342 , and the blank 41 ′ is ejected from the female mold 342 .
  • the conveying device turns the blank 41 ′ upside down and conveys the same to the first forging unit 31 to form the rough blank 42 .
  • the rough blank 42 is forged to form the prototype disc 43
  • the prototype disc 43 is forged to form the washer 5 .
  • step of trimming of this embodiment is performed after the blank 41 is obtained, this is advantageous in the subsequent forging forming steps to ensure neatness of an outer contour of the product. Further, since the step of trimming is added between the step of obtaining the blank 41 and the initial forging step, this may slow down the rate of deformation of the material, so that the mechanical properties of the washer 5 may be enhanced.
  • a method of making the washer 5 according to the third preferred embodiment of the present invention is shown to be similar to the first preferred embodiment.
  • the structure of the female mold of the second forging unit (not shown) is altered.
  • the prototype disc 43 is further formed with a middle protrusion 435 projecting from a middle of the central portion 433 .
  • the first and second central aligning indentations 424 , 425 are respectively formed in the central portion 433 and the middle protrusion 435 .
  • the third forging unit When the prototype disc 43 is conveyed to the third forging unit (not shown), the third forging unit will stamp and cut the central portion 433 and the middle protrusion 435 of the prototype disc 43 so that the prototype disc 43 is forged to form the washer 5 having the through hole 51 . Since the prototype disc 43 in this embodiment has the middle protrusion 435 projecting from the central portion 433 , the clamping tool (not shown) can clamp stably the middle protrusion 435 to thereby facilitate conveying of the prototype disc 43 .
  • the method of making the washer 5 according to the present invention includes the step of initially forging the rough blank 42 between the steps of obtaining the blank 41 and the forging of the prototype disc 43 , so that the blank 41 becomes the rough blank 42 first before becoming the prototype disc 43 , thereby slowing the rate of deformation of the material. This enhances the quality and mechanical properties of the washer 5 . Further, the uniformity of the thickness and the roundness of an outer periphery of the washer 5 are easily controlled compared to that of the conventional one-time forging method.
  • the independently obtained blank 41 is successively forged in the first to third forging units 31 , 32 , 33 , or is successively forged in the trimming device 34 and the first to third forging units 31 , 32 , 33 . Because the blank 41 undergoes the initial forging step to form the rough blank 42 and then two more forging steps, the impact force of the two forging steps are smaller than that used in the conventional single action forging method, such that the mold and the clamping tool are not as easily damaged and abraded. Hence, the service life of the forging equipment 3 can be prolonged. The object of the present invention can thus be realized.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)
US12/905,364 2009-04-09 2010-10-15 Method of making a washer Abandoned US20110034259A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
TW098111803 2009-04-09
TW098111803A TW201036731A (en) 2009-04-09 2009-04-09 Washer manufacturing method

Publications (1)

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US20110034259A1 true US20110034259A1 (en) 2011-02-10

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US12/905,364 Abandoned US20110034259A1 (en) 2009-04-09 2010-10-15 Method of making a washer

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US (1) US20110034259A1 (enrdf_load_stackoverflow)
TW (1) TW201036731A (enrdf_load_stackoverflow)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102773371A (zh) * 2011-05-09 2012-11-14 智品精密机械有限公司 无屑垫圈或螺帽的成型方法
CN111545624A (zh) * 2020-05-19 2020-08-18 邱焜 一种铜垫片冲压设备

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110883172B (zh) * 2019-12-25 2024-11-26 浙江鼎盛汽车紧固件有限公司 螺母垫圈冲压工艺及冲压装置
TWI811861B (zh) * 2021-11-24 2023-08-11 林冠泓 斷口華司與其製造方法
TWI804328B (zh) * 2022-05-24 2023-06-01 中國鋼鐵股份有限公司 墊圈成形方法及其擴孔模具

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2013758A (en) * 1935-03-23 1935-09-10 Clarence O Livermore Punch set
US2743466A (en) * 1951-01-04 1956-05-01 Nat Machinery Co Method of making skirted nuts
US4435973A (en) * 1981-11-25 1984-03-13 Nissan Motor Co., Ltd. Method of producing ring-shaped metal parts
US6065322A (en) * 1998-03-04 2000-05-23 Ntn Corporation Method and device for forming blanks for bearing rings

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2013758A (en) * 1935-03-23 1935-09-10 Clarence O Livermore Punch set
US2743466A (en) * 1951-01-04 1956-05-01 Nat Machinery Co Method of making skirted nuts
US4435973A (en) * 1981-11-25 1984-03-13 Nissan Motor Co., Ltd. Method of producing ring-shaped metal parts
US6065322A (en) * 1998-03-04 2000-05-23 Ntn Corporation Method and device for forming blanks for bearing rings

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102773371A (zh) * 2011-05-09 2012-11-14 智品精密机械有限公司 无屑垫圈或螺帽的成型方法
CN111545624A (zh) * 2020-05-19 2020-08-18 邱焜 一种铜垫片冲压设备

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TW201036731A (en) 2010-10-16
TWI358334B (enrdf_load_stackoverflow) 2012-02-21

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Date Code Title Description
AS Assignment

Owner name: CHUN ZU MACHINERY INDUSTRY CO., LTD., TAIWAN

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:LEE, SHI-CHANG;REEL/FRAME:025145/0405

Effective date: 20100923

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION