US3765218A - Method of manufacturing a component for use in a roller clutch assembly - Google Patents

Method of manufacturing a component for use in a roller clutch assembly Download PDF

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Publication number
US3765218A
US3765218A US00230563A US3765218DA US3765218A US 3765218 A US3765218 A US 3765218A US 00230563 A US00230563 A US 00230563A US 3765218D A US3765218D A US 3765218DA US 3765218 A US3765218 A US 3765218A
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United States
Prior art keywords
billet
preform
punch
slug
bore
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Expired - Lifetime
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US00230563A
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English (en)
Inventor
H Poulson
I Dockerill
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ZF International UK Ltd
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Lucas Industries Ltd
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Publication date
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass

Definitions

  • a component for a roller clutch assembly includes a sleeve having a head part and a shank part, and the component is produced by first cropping a steel bar to produce a slug having a length to diameter ratio of not less than 0.75. The slug is then deformed into a substantially cylindrical billet having a diameter-substantially equal to the diameter of the head part of the finished component. After heat treatment of the billet to remove work hardening, an axially extending, centrally disposed bore is formed in the billet and the bi]- let is positioned in a die.
  • a punch is used to perform a first impact extrusion process on the billet so that metal flows in the direction of movement of the punch and produces a preform defining the shank part of the sleeve and having a head portion which tapers inwardly to towards said shank part.
  • the preform is then heat treated to remove work hardening and a further punch is then used to perform a second impact extrusion process on the preform.
  • metal flows in the opposite direction to the direction of movement of the further punch and effects shaping of the preform so that the included angle of the tapering head portion of the preform is increased to produce the head part of the sleeve and thereby, the finished component.
  • This invention relates to a method of manufacturing a component for use in a roller clutch assembly, the component being of the kind including a sleeve having a head part and a shank part, the bore in the sleeve being stepped to define a wide portion within the head part and a narrow portion within the shank part, and the wall of said wide portion of the bore being shaped to define an internal cam surface in the head part.
  • a method according to the invention includes the steps of:
  • the minimum length to diameter ratio of the cropped slug is 1.
  • the tapering head portion produced at step (e) defines an included angle of between 80 and 100 C.
  • said included angle is increased to a value between 140 and 170 during the second impact extrusion step (g).
  • the second impact extrusion process is arranged to produce a plurality of angularly spaced ribs integral with the head part and extending inwardly from the wall of said wide portion of the bore.
  • step (d) is effected by a drilling operation.
  • step (d) is effected by an impact extrusion operation and then a piercing operation.
  • a tapered mandrel is positioned in the bore in the billet during the first extrusion process, the taper of the mandrel being such as to allow removal of the mandrel from the bore after formation of the preform without removal of the preform from the die.
  • FIG. 1 is a sectional view of a component for use in a roller clutch assembly.
  • FIGS. 2 to 6 are sectional views illustrating five stages respectively during a method according to a first example of the invention of producing the component shown in FIG. 1,
  • FIGS. 7 and 8 are sectional views illustrating two stages respectively during a method, according to a second example of the invention, of producingthe component shown in FIG. 1, and
  • FIG. 9 is a sectional view illustrating one stage during a method according to a modification of the second example.
  • a component for use in a roller clutch assembly the component being of the kind including a sleeve 9 having a head part 9a and a shank part 9b joined to the head part by a tapering portion 9c.
  • the bore 10 in the sleeve is stepped to define a wide portion 10a in the head part 9a and a narrow portion 10b in the shank part 9b, the wall of the wide portion 10a of the bore 10 defining an internal cam surface (not shown) in the head part 9a.
  • the component was manufactured from a bright drawn steel bar 11, the steel used in the bar 11 having the following composition by weight: carbon 0.21 percent, manganese 1.24 percent, silicon 0.3 percent, sulphur 0.033 percent, phosphorus 0.06 percent, nickel 0.13 percent, chromium 0.23 percent, molybdenum 0.15 percentand copper 0.15 percent, the remainder being iron.
  • the bar 11 was cropped by means of a tool 12 (FIG.
  • the feeding of the bar 11 into the cropping tool 12 being controlled by means of a fixed stop (not shown) so that the cropping operation produced a slug 13 of constant weight, the weight of the slug formed being determined by the volume of the slug necessary to produce a finished component of the desired dimensions.
  • the tool 12 was arranged to produce a slug 13 having a weight of 545 gm, the length of the slug being 43.4 mm and the diameter of the slug 44.45 mm. As shown in FIG.
  • the slug 13 was then formed by a press 14 into a billet 15 shaped so that the periphery of the billet 15 defined a substantially cylindrical surface with the diameter of the billet being substantially equal to the required head diameter of the finished component, which in the particular example was 58.9mm. Deforming of the slug 13 also reduced the length of the slug to a value of 26.4mm for the billet 15. i
  • a load of 350 tons was applied to the punches of the press 14 and after formation of the billet 15, a spheriodising heat treatment process was carried out by heating the billet for 4 hours at 680 C.
  • Lubrication was then applied to the billet by a standard phosphating and soaping application, whereafter an axially extending, centrally disposed bore 16 having a diameter of 20.5 mm, that is approximately 0.5mm larger than that required in the shank part 9b of the required component, was formed in the billet 15 by means of a drill 17 (FIG. 4) and the drilled billet was positioned in an extrusion die 18.
  • the deformation of the slug 13 by the press 14 was arranged to produce an annular ring (not shown) on the periphery of the billet 15, the width of the ring being controlled so as to prevent creation of large stresses in the tools during subsequent operations.
  • a first impact extrusion process was carried out on the billet 15 by applying a pressure of 288 tons to the billet 15 through a first extrusion punch 19.
  • metal flowed from the billet 15 in the direction of movement of the punch 19 the die 18 being arranged so that the extrusion produced a preform 21 having a shank portion 21b, defining the shank part 9b of the required component, and a head portion 21a of diameter equal to the diameter of the head part 9a of the required component.
  • the extrusion process also produced a tapering portion 21c joining the head portion 21a and the shank portion 21b, the taper of the portion 21c being such that the included angle of the taper was 80.
  • a mandrel 22 extending through the punch 19 was received in the bore 16 in the billet during the extrusion process so that the extrusion produced a bore in the preform 21, which was of course required since the finished component is in the form of a sleeve 9 having a bore 10 extending therethrough. Further, the mandrel 22 was provided with a slight taper so as to allow the mandrel to be removed from the preform after extrusion without the preform being removed from the die 18.
  • the preform 21 was ejected from the die by means of an ejector punch 23 and subsequently it was heat treated at 680 C for 4 hours.
  • the preform 21 was then lubricated by a standard phosphating and soaping treatment and subsequently was positioned in a further die 24 (FIG. 6) and a second impact extrusion process was carried out on the preform.
  • extrusion was effected by applying a load of 242 tons through a second extrusion punch 25 to the free end of the head portion 21a of the preform.
  • a further mandrel 26 was positioned in the bore in the preform 21 and the free end of the shank portion 21b of the preform was held against movement by a stationary punch 27, whereby application of pressure to the preform 21 through the punch 26 caused flow of metal in the opposite direction to the direction of movement of the punch.
  • the arrangement of the die 24 was such that the flow of metal during this backward extrusion process further shaped the preform 21 to define the head part 9a of the sleeve 9 and thereby produce the required component.
  • the tapered portion 21c of the preform 21 was reshaped to produce the tapering portion 90 of the component 9, the included angle of the taper being increased to value of 140 for the portion 9c.
  • the punch 25 is arranged so that the backward extrusion process produces the required internal cam surface in the head part 9a. Furthermore the punch 25 is shaped so that the backward extrusion process produces a plurality of integral, angularly spaced ribs 28 which extend inwardly from the wall of the wide portion 10a of the bore 10. In a roller clutch assembly, each of the ribs 28 defines an abutment against which a spring is flexed so as to urge a roller into engagement with the cam surface on the wall of the wide portion 10a of the bore 10.
  • the bore in the preform 21 will also be tapered.
  • the second extrusion process will remove the taper from the bore in the preform 21 so that the bore 10b in the shank part 9b of the sleeve 9 will be of the required constant diameter.
  • the component 9 was manufactured from a centreless, turned steel bar having the same chemical composition as the bar 11 of the first example.
  • the bar was cropped as before to produce a slug, the weight of the slug now being between 480 and 500 grams and the diameter and length of the slug being 1.63 inch and 1.88 inch respectively.
  • the deforming operation was carried out in the same way as shown in FIG. 3 for the first example, with a load of 350 tons being applied to the punches of the press 14.
  • the billet produced by the deforming operation had a diameter of 2.288 inch and a length of 0.975 inch.
  • the billet was then spheroidised by heating for 4 hours at 680 C, whereafter lubrication was applied to the billet by a standard phosphating and soaping application.
  • the tip 34 of the punch 33 was formed of tungsten carbide sold by Wickman Wimet as grade C.T., which contained 9 percent by weight of cobalt, had a grain size of 3 microns, and a density of 14.65 gm/c.c.
  • a tool steel punch holder 35 supported the carbide punch tip 34 and a high speed steel backing piece 36 which formed the other part of the two-part punch 33.
  • a load of 73 tons was applied to the punch 33 to effect the bore extrusion which produced a cylindrical, blind bore in the billet 31 of diameter 0.803 inch, the length and external diameter of the billet, after extrusion, being 1.200 inch and 2.298 inch respectively.
  • the pierced billet was then heat treated to recrystalise the work hardened ferrite grains in the steel by passing the billet through a conveyor furnace at a speed of 2.5 inches per minute with the furnace temperature being held at 710720 C and the furnace being supplied with exothermic gas. After recrystalisation, the billet was lubricated using a standard phosphating and soaping treatment and was then extruded, in the manner of the first example, to produce a preform 21 (FIG. 5).
  • a roller clutch component similar to that shown at 9 in FIG. 1.
  • the component of this modification was required to define, between its head portion and its shank portion, a tapering portion such that the included angle of the taper was 170.
  • the method of producing the component was substantially the same as that of the second example.
  • a centreless, turned steel bar was first cropped to produce a slug of weight between 215 and 220 grams, of diameter 1.260 inch and of length 1.240 inch.
  • the slug was then deformed into a substantially cylindrical billet of diameter 1.832 inch and axial length 0.676 inch by applying a load of 260 tons to the slug by means of the punches of a press similar to that shown in P16. 3. Then, following lubrication of the billet, an axially extending, centrally disposed bore was produced in the billet by an impact extrusion operation and then a piercing operation.
  • the impact extrusion operation which is illustrated in FlG. 9, followed closely the corresponding operation in the previous example, although in this case it was required to produce a tapering bore in the billet so that the punch tip, shown at 41, was tapered also.
  • the punch tip 41 was formed of grade C.T.
  • the resultant pierced billet had an external diameter OH .839 inch, and an axial length of 0.800 inch, and had a tapering bore of mean diameter 0.662 inch and an angle of taper of 2 28.
  • Each of the components produced in the examples described above is particularly designed for use as a roller clutch sleeve for a starter motor. It will therefore be appreciated that further processing of the finished component is required to produce helical grooves in the wall of the narrow portion b of the bore 10 for engagement with complementary splines on the rotor shaft of the starter motor.
  • a method of manufacturing a component of the kind specified for use in a roller clutch assembly including the steps of:
  • thermo treatment step (f) is a spheroidising operation.
  • step (d) is effected by-a drilling operation.
  • step (d) is effected by an impact extrusion operation and then a piercing operation.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)
  • Mechanical Operated Clutches (AREA)
US00230563A 1971-03-05 1972-03-01 Method of manufacturing a component for use in a roller clutch assembly Expired - Lifetime US3765218A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB621871A GB1367096A (en) 1971-03-05 1971-03-05 Method of manufacturing a component for use in a roller clutch method of manufacturing a component for use in a roller clutch assembl y

Publications (1)

Publication Number Publication Date
US3765218A true US3765218A (en) 1973-10-16

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US00230563A Expired - Lifetime US3765218A (en) 1971-03-05 1972-03-01 Method of manufacturing a component for use in a roller clutch assembly

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US (1) US3765218A (enExample)
AR (1) AR194358A1 (enExample)
DE (1) DE2210501C2 (enExample)
ES (1) ES400662A1 (enExample)
FR (1) FR2128006A5 (enExample)
GB (1) GB1367096A (enExample)
IT (1) IT952089B (enExample)
ZA (1) ZA721117B (enExample)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4341106A (en) * 1977-04-13 1982-07-27 Gleason Works Apparatus for controlling the movement of a reciprocatory hydraulically driven element of a metal forming machine
US5088311A (en) * 1989-06-21 1992-02-18 Ngk Spark Plug Co., Ltd. Method of making a tubular member
CN104668906A (zh) * 2015-01-29 2015-06-03 中南大学 一种超越离合器的斜撑块的制造工艺
CN111015083A (zh) * 2019-11-14 2020-04-17 浙江格雷特科技股份有限公司 一种离合器助力器壳体的加工工艺

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2308347C2 (ru) * 2005-09-20 2007-10-20 Мемжанов Николай Османович Способ изготовления деталей типа втулок, имеющих сквозную полость и наружную поверхность с переменным вдоль оси сечением

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1693957A (en) * 1922-04-28 1928-12-04 Bridgeport Brass Co Method of making battery nuts
US1829558A (en) * 1930-06-27 1931-10-27 Roy H Smith Method of making nut blanks
US1916432A (en) * 1929-07-06 1933-07-04 Internat Safety Lock Nut Corp Apparatus for manufacturing forgings
US3283556A (en) * 1961-03-24 1966-11-08 Textron Inc Apparatus for forming articles
US3595058A (en) * 1969-01-28 1971-07-27 Reynolds Metals Co Method of forming slugs from rod stock
US3651683A (en) * 1969-03-15 1972-03-28 Rudolf Liebergeld Cold moulding press

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH103565A (fr) * 1922-09-22 1924-03-01 Caswell Huntoon William Procédé et machine pour la fabrication d'une ébauche de tube compressible et ébauche obtenue par ledit procédé.
US2216201A (en) * 1934-12-22 1940-10-01 Gen Motors Corp Method of making tubular inserts
CH317554A (de) * 1952-09-30 1956-11-30 Bosch Gmbh Robert Verfahren zum Fliesspressen von Hohlkörpern
GB862975A (en) * 1957-03-25 1961-03-15 Kabel Und Metallwerke Neumeyer Improvements relating to the production of valve spring-retainers

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1693957A (en) * 1922-04-28 1928-12-04 Bridgeport Brass Co Method of making battery nuts
US1916432A (en) * 1929-07-06 1933-07-04 Internat Safety Lock Nut Corp Apparatus for manufacturing forgings
US1829558A (en) * 1930-06-27 1931-10-27 Roy H Smith Method of making nut blanks
US3283556A (en) * 1961-03-24 1966-11-08 Textron Inc Apparatus for forming articles
US3595058A (en) * 1969-01-28 1971-07-27 Reynolds Metals Co Method of forming slugs from rod stock
US3651683A (en) * 1969-03-15 1972-03-28 Rudolf Liebergeld Cold moulding press

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4341106A (en) * 1977-04-13 1982-07-27 Gleason Works Apparatus for controlling the movement of a reciprocatory hydraulically driven element of a metal forming machine
US5088311A (en) * 1989-06-21 1992-02-18 Ngk Spark Plug Co., Ltd. Method of making a tubular member
CN104668906A (zh) * 2015-01-29 2015-06-03 中南大学 一种超越离合器的斜撑块的制造工艺
CN111015083A (zh) * 2019-11-14 2020-04-17 浙江格雷特科技股份有限公司 一种离合器助力器壳体的加工工艺

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Publication number Publication date
ES400662A1 (es) 1975-02-16
AR194358A1 (es) 1973-07-13
DE2210501C2 (de) 1981-12-24
ZA721117B (en) 1972-11-29
DE2210501A1 (de) 1972-09-14
GB1367096A (en) 1974-09-18
IT952089B (it) 1973-07-20
FR2128006A5 (enExample) 1972-10-13

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