WO2023123833A1 - 一种单向器星轮滚柱室冷挤压凸模及其制造方法 - Google Patents

一种单向器星轮滚柱室冷挤压凸模及其制造方法 Download PDF

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Publication number
WO2023123833A1
WO2023123833A1 PCT/CN2022/094598 CN2022094598W WO2023123833A1 WO 2023123833 A1 WO2023123833 A1 WO 2023123833A1 CN 2022094598 W CN2022094598 W CN 2022094598W WO 2023123833 A1 WO2023123833 A1 WO 2023123833A1
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punch
mold
cold extrusion
blank
guide surface
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PCT/CN2022/094598
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English (en)
French (fr)
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李福兴
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玉环普天单向器有限公司
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Publication of WO2023123833A1 publication Critical patent/WO2023123833A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C25/00—Profiling tools for metal extruding
    • B21C25/02—Dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C25/00—Profiling tools for metal extruding
    • B21C25/10—Making tools by operations not covered by a single other subclass

Definitions

  • the invention belongs to the technical field of punching dies, and relates to a punch, in particular to a cold extrusion punch for a star wheel roller chamber of a checker and a manufacturing method thereof.
  • the one-way device is a key part of the starter motor.
  • the one-way device includes a housing and a starting gear installed in the housing. There are multiple rollers around the outer side of the starting gear.
  • the side of the inner cavity of the housing at each roller is Both have eccentric arc surfaces, and the rollers can roll within the range where the eccentric arc surfaces are located.
  • the working principle of the one-way device is: when the shell rotates forward, the roller rolls toward the side where the radius of the eccentric arc surface gradually decreases, and the guide rollers that are subjected to the eccentric arc surface gradually approach the starting gear and finally tightly fit with the starting gear so that the shell The body and the starting gear rotate synchronously; when the housing is reversed, the roller rolls towards the side where the radius of the eccentric arc surface gradually increases, so that there is a gap between the roller and the starting gear, and the rotation of the housing cannot drive the starting gear to rotate synchronously.
  • the engine speed is higher than that of the starter, so that the engine will turn with the starter and damage the starter, so a one-way device can be used to reverse the skid The role of protecting the starter motor.
  • the inner cavity of the existing one-way device housing is generally formed by cold extrusion at one time. Since the side of the inner cavity has an eccentric arc surface and a protrusion for the limit roller, the punch used is also based on the single According to the design of the outer peripheral surface of the punch, there will be many convex and concave parts. During cold extrusion, such an uneven punch will enter the mold due to the excessive contact area in the circumferential direction and the And other factors lead to very huge resistance, which makes it very difficult for the punch to enter the mold. Usually we increase the thrust force of the punch to hard squeeze the inner cavity of the one-way device, but this will make the outer edge of the punch circumferentially protruding very easily to wear or suffer from stress fracture.
  • the object of the present invention is to solve the above-mentioned problems in the prior art, and propose a cold extrusion punch for the star wheel roller chamber of the checker. It solves the technical problem of allowing the punch to enter the mold smoothly on the basis of ensuring that the roller chamber of the one-way device produced by cold extrusion is normally installed with rollers.
  • a cold extrusion punch for a star wheel roller chamber of a non-reversing device comprising a columnar body with an entry end and an ejection end, the body has several protrusions for extruding the roller chamber in the circumferential direction , the outside of the convex portion has an arc surface, and the end surface of the mold entry end is a plane perpendicular to the axis of the body. It is characterized in that the end surface of the convex portion located on the side of the mold entry end has a mold entry guide surface , the guide surface of the mold entry is inclined towards the demoulding end relative to the plane one, and each guide surface of the mold entry is located on the side where the arc surface is located. The two are parallel to each other.
  • each convex part of this design is provided with a mold-in guide surface, and the mold-in guide surface on each convex part protruding from the outer periphery of the body is directly in rigid contact with the one-way housing when entering the mold.
  • the guide surface inclined from the inside to the outside allows the convex part to guide forward, and the resistance on the convex part will be greatly reduced, so that the resistance of the entire punch will decrease, and the punch will enter the mold very smoothly.
  • the arc surface on the convex part is used to extrude the eccentric arc surface of the roller chamber.
  • the roller chamber installed on the eccentric arc surface will guide and roll along the eccentric arc surface and will not fall out of the eccentric arc surface.
  • the end surface of the convex part is provided with a guide surface for entering the mold.
  • the guide surface for entering the mold is an inclined surface. After extrusion, leaving an inclined surface at the bottom of the roller chamber of the one-way device is not conducive to the installation of the rollers, so this design is on the guide surface for entering the mold.
  • a depression is set on the inner side of the curved surface above, and the bottom surface of the depression is a plane, so that after cold extrusion, a boss will be left at the bottom of the inner cavity of the one-way device, and the corresponding boss is located on the eccentric arc surface.
  • the end face of the bosses is flat so that the rollers can work normally.
  • the rollers will not fall out of the bosses because they are guided by the eccentric arc surface, and the rollers in the roller chamber are guaranteed.
  • the entire punch enters the mold very smoothly.
  • each convex part includes an eccentric arc part and a limit part
  • the arc surface is the outer surface of the eccentric arc part
  • the limit part The intersection of the outer surface of the part and the arc surface has an inwardly concave arc surface, and the concave part is provided on the end of the eccentric arc part.
  • the arc surface is the outer surface of the eccentric arc part.
  • the eccentric arc part forms a roller chamber on the one-way housing for the roller movement.
  • the roller rolls out of the roller chamber, and the concave part keeps the bottom surface of the extruded roller chamber flat, while the end surface at the limit part is an inclined guide surface for entering the mold, ensuring that the extruded roller chamber On the basis of normal installation of rollers, the punch enters the mold more smoothly.
  • the body can be divided into a stripping section and a working section along its length, and the body is located in the radial section of the stripping section.
  • the area gradually decreases from the side close to the working section to the side away from the working section, and the shape of the radial cross-section of the main body located on the demoulding section is the same everywhere, and the mold-in guide surface and the concave part are located on the main body of the working section .
  • the main body can be divided into a demoulding section and a working section along its length direction.
  • the shape of the radial section of the main body of the demoulding section along its length direction is the same, and the demoulding section is from the side close to the working section to the side away from the working section.
  • the radial cross-sectional area on one side of the section gradually decreases, and the demoulding section is equivalent to gradually shrinking from one side close to the working section to the other side.
  • the proportional reduction of the die section can reduce the contact area between the outer peripheral surface of the punch and the inner cavity wall of the one-way housing during extrusion, and the smaller the contact area, the smaller the friction force, making it easier to enter the mold. smooth.
  • the length of the stripping section is much longer than that of the working section.
  • the length of the working section is much smaller than the length of the stripping section, so that the working section and the one-way There is less contact between the housings and less resistance, resulting in smoother entry into the mold.
  • all the mold entry guide surfaces are arranged around the center line of the body.
  • All the mold-entry guide surfaces on the protrusions are set outwardly with the axis of the body as the center, and all the mold-entry guide surfaces look like an annular inclined surface when combined. Let the end of the punch appear to have a certain taper, and the resistance of the end of the punch will be greatly reduced compared with the flat end surface when the punch is advanced, making the entry into the mold very smooth.
  • the end surface of the working section is provided with an annular inclined surface along its circumference, and each mold entry guide surface is flush with the inclined surface.
  • the annular inclined surface on the end face of the working section also acts as a guide when entering the mold and can effectively reduce resistance.
  • the guide surface on the convex part is connected with the inclined surface and is flush, so that the combination forms a complete
  • the guide surface can greatly reduce the resistance of the upper working section when entering the mold, making the entry of the punch very smooth.
  • a method for manufacturing a cold extrusion punch of a star wheel roller chamber of a one-way device characterized in that the method comprises the following steps:
  • blank punch preparation first turn the outer periphery of the blank, and then heat-treat the blank to obtain the blank punch;
  • the second step finishing turning: use a lathe to turn the outer edge of the end face of the blank punch to form a ring-shaped guide surface;
  • the third step, wire cutting use a wire cutting machine to perform slow wire cutting on the blank punch, the convex part is formed on the outer periphery of the blank punch by wire cutting, and the concave part is formed on each convex mold by wire cutting.
  • the arc surface is formed on the outer surface of the convex part by wire cutting, and the guide surface is formed into a mold guide surface at each convex part by wire cutting;
  • the fourth step electrochemical corrosion: put the blank punch into the electrolyte and set a ring-shaped electrode sheet on one end of the blank punch, and the end of the blank punch located on the inner side of the electrode sheet is obtained by electrolytic corrosion A stripping section with a gradually smaller cross-sectional area, the blank punch is located at one end outside the electrode sheet to form a working section;
  • the fifth step, polishing polishing the blank punch to get the finished punch.
  • the processing of the mold entry guide surface in this design needs to cut out the entire ring-shaped guide surface along its circumference on the end surface of the blank punch, and then directly divide the guide surface into individual mold entry when cutting the convex part on the line.
  • Guide surface such processing is very convenient so that the punch enters the mold very smoothly when cold extruding the one-way device housing.
  • the inclined surface on the end surface of the punch is actually a part of the smaller inner diameter of the guide surface, which can also provide a good guiding effect during extrusion, so that the punch enters the mold very smoothly.
  • the demoulding section is processed by electrochemical corrosion. Put the whole rough blank punch into the electrolyte, put the ring-shaped electrode piece on one end of the rough blank punch, and the electrode piece will energize the blank punch. Electrolytic corrosion is carried out on the end of the mold sleeve with the electrode sheet, while the exposed part of the blank punch outside the electrode sheet will not participate in the electrolytic corrosion and retain the original size to form a working section.
  • the diameter of the working section is larger than the diameter of the stripping section.
  • the working section is directly extruded with the one-way housing to form its inner cavity. This design effectively reduces the contact area between the punch and the one-way housing, making the mold entry smoother, and the demoulding section is proportionally reduced. This punch can be easily taken off when demoulding.
  • the minimum diameter of the guide surface in the second step is the diameter of the starting gear in the one-way device + 1.5 times the diameter of the rollers
  • the maximum diameter of the guide surface is the maximum diameter of the blank punch.
  • the length of the working section in the fifth step is 2mm-2.5mm.
  • the cross-sectional shape of the electrode piece in the fifth step is the same as the cross-sectional shape of the rough blank punch after wire cutting, and
  • the cross-sectional area of the electrode sheet gradually decreases in proportion from one end to the other end, and the blank punch is extended from the end with a larger opening of the electrode sheet.
  • each convex part of this design is provided with a mold-in guide surface, and the mold-in guide surface on each convex part protruding from the outer periphery of the body is directly in contact with the one-way housing when entering the mold.
  • the inclined mold entry guide surface in rigid contact greatly reduces the resistance encountered by the convex part when it enters, so that the resistance of the entire punch decreases, and the punch enters the mold very smoothly.
  • the inner cavity of the one-way housing is extruded by the working section, and the stripping section does not participate in the extrusion, so the length of the working section is much smaller than the length of the stripping section, so that the working section and the one-way There is less contact between the housings and less resistance, resulting in smoother entry into the mold.
  • a concave part is set on the inner side of the arc surface on the guide surface of the mold.
  • the bottom surface of the concave part is a plane.
  • Fig. 1 is a structural representation of the present invention
  • Fig. 2 is a top view of the present invention
  • Fig. 3 is a half-sectional schematic diagram of the present invention in the A-A direction of Fig. 2;
  • Fig. 4 is a half-sectional view of the present invention along the B-B direction of Fig. 2 .
  • a kind of one-way star wheel roller room cold extrusion punch and its manufacturing method include a columnar body 1, and the center of the body 1 has a mounting and fixing pin for fixing with the bearing.
  • the central hole 17, the body 1 has six convex parts 2 evenly distributed in the circumferential direction for extruding the roller chamber, so that the entire body 1 looks like a hexagonal shape, and the outer sides of the convex parts 2 have arc surfaces 211,
  • the end face of the body 1 is a plane-13 perpendicular to its axis, and the end face of the die-entry end 15 of the body 1 is located at each convex portion 2 and has an inclined die-in guide surface 23, which is close to the center line of the body.
  • Each molding guide surface 23 is provided with a concave portion 24 on the side where the arc surface 211 is located.
  • the bottom surface of the concave portion 24 is a plane 2 241 and the plane 13 and the plane 2 241 are parallel to each other.
  • the end face of each convex portion 2 of this design is provided with a mold entry guide surface 23, and the mold entry guide surface 23 on each convex portion 2 protruding from the outer periphery of the body 1 when entering the mold is directly and one-way.
  • the inclined die-in guide surface 23 which is in rigid contact with the housing of the device greatly reduces the resistance encountered by the convex part 2 when it enters, so that the resistance of the entire punch is reduced, and the punch-in-mold advances very smoothly.
  • the mold entry guide surface 23 is set on the end face of the convex part 2.
  • the mold entry guide surface 23 is an inclined surface 14.
  • the inner side of the curved surface 211 on the mold guide surface 23 is provided with a concave portion 24, and the bottom surface of the concave portion 24 is a plane, so that after cold extrusion, a boss will be left at the bottom of the inner cavity of the one-way device.
  • the main body 1 can be divided into a working section 11 and a demoulding section 12 along its length direction.
  • the mold entry guide surface 23 and the concave part 24 are all located on the convex part 2 on the working section 11.
  • the outer circumference diameter of the convex part 2 on the working section 11 is remain unchanged, while the cross-sectional shape of the stripping section 12 along its length direction is the same, but the size of the cross-section is proportionally reduced from close to the working section 11 to away from the working section 11.
  • the working section 11 is in direct contact with the housing of the one-way device, and the stripping section 12 is proportionally reduced to allow the outer peripheral surface of the punch to be in contact with the inner cavity wall of the one-way device housing.
  • the length of the stripping section 12 is much longer than that of the working section 11 .
  • the length of the working section 11 is 2mm-2.5mm, and the working section 11 is equivalent to the function of the working belt.
  • the inner cavity of the one-way housing is extruded by the working section 11, and the demoulding section 12 does not participate in it.
  • the length of the working section 11 is much smaller than the length of the demoulding section 12, so that the contact between the working section 11 and the one-way housing is less, the resistance received is smaller, and it is smoother when entering the mold.
  • An annular inclined surface 14 is provided on the end surface of the working section 11 along its circumference, and each mold-introduction guide surface 23 is flush with the inclined surface 14 .
  • the annular inclined surface 14 on the end face of the working section 11 also acts as a guide when entering the mold and can effectively reduce resistance.
  • the mold entry guide surface 23 on the convex part 2 is connected with the inclined surface 14 and is flush. Forming a complete guide surface in this way can greatly reduce the resistance of the working section 11 when entering the mold, so that the entry of the punch into the mold becomes very smooth.
  • Each convex portion 2 includes two parts, left and right, respectively eccentric arc portion 21 and limit portion 22.
  • the arc surface 211 is the outer surface of the eccentric arc portion 21.
  • the eccentric arc portion 21 is mainly capable of extruding the roller chamber, rolling
  • the side of the column chamber is the same as the arc surface 211, and the stopper 22 is capable of extruding out the protruding protrusion of the stopper 22 and the arc surface 211, which can restrict the rollers from rolling out of the roller chamber.
  • the arc surface 25 and the recessed portion 24 are provided on the end of the eccentric arc portion 21 .
  • the concave part 24 is only provided on the eccentric arc part 21 to keep the bottom surface of the extruded roller chamber flat, while the end surface at the limit part 22 is an inclined mold entry guide surface 23, allowing the punch to enter the mold more smoothly.
  • the punch of this design can be produced and processed by the following methods: the first step, blank punch preparation: first turn the outer periphery of the blank, and then heat treat the blank to obtain the blank punch; the second step, finish turning : Use a lathe to turn the outer edge of the end face of the blank punch to form a ring-shaped guide surface, and the inclination angle of the guide surface is almost 4 degrees; the third step, wire cutting: use a wire cutting machine to slowly cut the blank punch Wire cutting, the convex part 2 is formed on the outer periphery of the blank punch by wire cutting, the concave part 24 is formed on the end of each convex part 2 by wire cutting, and the arc surface 211 is formed on the outside of the convex part 2 by wire cutting On the side, the guide surface is formed into the mold guide surface 23 at each convex part 2 by wire cutting; the fourth step, electrochemical corrosion: put the blank punch into the electrolyte and set it on one end of the blank punch Ring-shaped electrode sheet, the end of the blank
  • the processing of the mold entry guide surface 23 of this design needs to cut out the entire annular guide surface along its circumference on the end surface of the blank punch, and then directly divide the guide surface into individual pieces when cutting the convex part 2 online. Die entry guide surface 23, such processing is very convenient to make this punch enter the mold very smoothly when cold extruding the one-way device housing.
  • the inclined surface 14 on the end face of the punch is actually a part of the inner diameter of the guide surface, which can also provide a good guiding effect when extruding, so that the punch enters the mold very smoothly.
  • the demoulding section 12 is processed by electrochemical corrosion.
  • the minimum diameter of the guide surface in the second step is the diameter of the starting gear in the one-way device + 1.5 times the diameter of the roller, and the maximum diameter of the guide surface is the maximum diameter of the blank punch.
  • the cross-sectional shape of the electrode sheet used in the fifth step is also a six-flower shape, its minimum inner diameter is slightly larger than the maximum outer diameter of the blank punch, and the electrode sheet gradually shrinks, and the cross-sectional area of the electrode sheet is from one end to the other end The equal proportion is gradually reduced, and the blank punch is extended from the larger end of the electrode sheet opening. After electrochemical corrosion, one end of the blank punch has a demoulding angle of 7 degrees.

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Abstract

本发明提供了一种单向器星轮滚柱室冷挤压凸模及其制造方法，属于冲压模具技术领域。它解决了在保证冷挤压出来的单向器滚柱室正常安装滚柱的基础上让凸模入模顺畅的问题。本凸模包括呈柱状的本体，本体的周向具有若干用于挤压出滚柱室的凸部，凸部的外侧均具有弧面，入模端的端面为与本体轴线相垂直的平面一，凸部位于入模端一侧的端面上具有倾斜的入模导向面，每个入模导向面上均设有凹陷部。本设计的凸模在冷挤压过后会在单向器的内腔底部留下凸台，凸台的端面为平面能让放置在其上的滚柱正常工作，滚柱由于受到偏心弧面导向滚动不会掉出凸台外，在保证了滚柱室内的滚柱正常安装工作的基础上，使得整个凸模入模十分顺畅。

Description

一种单向器星轮滚柱室冷挤压凸模及其制造方法 技术领域
本发明属于冲压模具技术领域，涉及一种凸模，尤其涉及一种单向器星轮滚柱室冷挤压凸模以及其制造方法。
背景技术
单向器是起动电机上的一个关键部件，单向器包括壳体和安装在壳体内的启动齿轮，启动齿轮的外侧环绕有多个滚柱，每个滚柱处的壳体的内腔侧面上都具有偏心弧面，滚柱能在偏心弧面所在的范围内滚动。单向器的工作原理是：当壳体正转时，滚柱朝向偏心弧面半径逐渐缩小一侧的滚动，受到偏心弧面的导向滚柱逐渐靠近启动齿轮并最终与启动齿轮紧配合使得壳体与启动齿轮同步转动；当壳体反转时，滚柱朝向偏心弧面半径逐渐增大一侧滚动使得滚柱与启动齿轮之间产生间隙，壳体转动无法带动启动齿轮同步转动。当汽车启动后在起动机没有停止工作的那一刹那发动机的转速要高于起动机，这样发动机就会带着起动机转了会损害起动机，所以要用到单向器能起到反向打滑的作用，起到保护起动电机。
现有的单向器壳体的内腔一般是采用冷挤压一次成型的，由于内腔的侧面具有偏心弧面以及用于限位滚柱的凸出，所以使用到的凸模也是根据单向器的内腔形状而特别制造的，根据设计凸模的外周面会具有多处凸部和凹部，在冷挤压时这样凹凸不平的凸模在入模时由于周向的接触面积过大以及等因素导致阻力十分巨大使得凸模入模十分困难。通常我们都是增加凸模推进力硬挤压出单向器的内腔，但是这样会使得凸模周向凸出的外沿处极易 容易出现磨损或受到应力断裂。
发明内容
本发明的目的是针对现有技术存在的上述问题，提出了一种单向器星轮滚柱室冷挤压凸模。它解决的是在保证冷挤压出来的单向器滚柱室正常安装滚柱的基础上让凸模入模顺畅的技术问题。
本发明的目的可通过下列技术方案来实现：
一种单向器星轮滚柱室冷挤压凸模,包括具有入模端和脱模端且呈柱状的本体，所述本体的周向具有若干用于挤压出滚柱室的凸部，所述凸部的外侧均具有弧面，所述入模端的端面为与本体轴线相垂直的平面一，其特征在于，所述凸部位于入模端一侧的端面上具有入模导向面，所述入模导向面相对平面一朝向脱模端方向倾斜，每个入模导向面上位于弧面所在一侧均设有凹陷部，所述凹陷部的底面为平面二且平面一和平面二相互平行。
本设计的每个凸部的端面处均设置有入模导向面，在入模时凸出在本体外周上的每个凸部上的入模导向面都是直接与单向器壳体刚性接触的由内向外倾斜的入模导向面让凸部导向前进，凸部所受到的阻力会大幅度的降低，使得整个凸模阻力下降，进而凸模入模前进的十分顺畅。
凸部上的弧面是用于挤压出滚柱室内的偏心弧面用的，滚柱安装在偏心弧面处的滚柱室内会沿着偏心弧面导向滚动并且不会脱离偏心弧面外。在凸部的端面上设置入模导向面，入模导向面是倾斜面在挤压过后在单向器的滚柱室底部留下斜面不利于滚柱的安装，所以本设计在入模导向面上的弧面的内侧处设置凹陷部，凹陷部的底面为平面，这样在冷挤压过后在单向器的内腔底部会留下凸台，凸台对应的位于偏心弧面处我们只需要将滚柱放置在 凸台上即可，凸台的端面为平面能让滚柱正常工作，滚柱由于受到偏心弧面导向滚动不会掉出凸台外，在保证了滚柱室内的滚柱正常安装工作的基础上，使得整个凸模入模十分顺畅。
在上述的一种单向器星轮滚柱室冷挤压凸模中，每个凸部均包括偏心弧部和限位部，所述弧面为偏心弧部的外侧面，所述限位部的外侧面与弧面相交处具有向内凹陷的弧面，所述凹陷部开设在偏心弧部的端部上。
弧面即为偏心弧部的外侧面，偏心弧部在单向器壳体上形成用于滚柱运动内的滚柱室，限位部则是在滚柱室一侧形成凸出能限制滚柱滚出滚柱室外，凹陷部则是让挤压出来的滚柱室的底面保持平面，而限位部处的端面则是为倾斜的入模导向面，在保证挤压出来的滚柱室正常安装滚柱的基础上让凸模入模更加顺畅。
在上述的一种单向器星轮滚柱室冷挤压凸模中，所述本体沿其长度方向上可分为脱模段和工作段，所述本体位于脱模段上的径向截面面积由靠近工作段一侧至背离工作段一侧逐渐变小且本体位于脱模段上各处的径向截面的形状均相同，所述入模导向面和凹陷部均位于工作段的本体上。
本体沿其长度方向上可以分为脱模段和工作段，脱模段的本体上沿其长度方向上的各处径向截面的形状均相同且脱模段由靠近工作段一侧至背离工作段一侧的径向截面面积逐渐缩小，脱模段相当于由靠近工作段一侧至另一侧等比例逐渐缩小，本体在使用时是工作段与单向器壳体接触挤压的，脱模段等比例缩小在挤压时能让凸模的外周面能与单向器壳体的内腔壁的接触面积变小，接触面积变小则摩擦力也会变小，使得入模的时候更加顺畅。而且在单向器内腔挤压出成型之后脱模段外廓面与单向器内腔壁之间会具有一定间隙，这样有利凸模的脱模，让凸模脱模也变得十分顺畅。
在上述的一种单向器星轮滚柱室冷挤压凸模中，所述脱模段的长度远大于工作段的长度。
实际在凸模入模时是靠工作段挤压出单向器壳体的内腔，脱模段不参与挤压，这样工作段的长度远小于脱模段的长度，使得工作段与单向器壳体之间的接触更少，受到的阻力更小，则入模时更加顺畅。
在上述的一种单向器星轮滚柱室冷挤压凸模中，所有的入模导向面均环绕本体中心线设置。
所有的凸部上的入模导向面均以本体轴线为中心向外倾斜设置，所有的入模导向面组合起来看起来像是一个环形的倾斜面。让凸模的端部看起来带有一定锥度，这样的凸模端部在入模前进时相较之平面的端面所受到的阻力会大大降低，使得入模变得十分的顺畅。
在上述的一种单向器星轮滚柱室冷挤压凸模中，所述工作段的端面上沿其周向设有环状的倾斜面，每个入模导向面均与倾斜面齐平。
工作段的端面上的环形的倾斜面的也是起到入模时起到导向的作用能有效的减少阻力，凸部上的入模导向面与倾斜面相连接且齐平，这样组合形成一个完整的导向面能让上工作段在入模的时候受到的阻力得到大大的降低，让凸模的入模变得十分顺畅。
一种单向器星轮滚柱室冷挤压凸模的制造方法，其特征在于，本制造方法包括以下步骤：
第一步，毛胚凸模准备：先对胚料的外周进行车削，然后对胚料进行热处理得到毛胚凸模；
第二步，精车：使用车床对毛胚凸模的端面的外沿进行车削形成环状的导向面；
第三步，线切割：使用线切割机对毛胚凸模进行慢走丝线切 割，所述凸部通过线切割成型于毛胚凸模的外周，所述凹陷部通过线切割成型于每个凸部的端部上，所述弧面通过线切割成型于凸部的外侧面上，所述导向面通过线切割在每个凸部处形成入模导向面；
第四步，电化学腐蚀：将毛胚凸模放入电解液中并在毛胚凸模的一端套设环状的电极片，所述毛胚凸模位于电极片内侧的一端通过电解腐蚀得到截面积逐渐变小的脱模段，所述毛胚凸模位于电极片外的一端形成工作段；
第五步，抛光：将毛胚凸模进行抛光得到成品凸模。
本设计的入模导向面的加工需要现在毛胚凸模的端面上沿其周向切出整个环状的导向面，然后在线切割出凸部的时候直接将导向面分割成一个个的入模导向面，这样的加工十分方便使得本凸模在冷挤压单向器壳体时入模十分顺畅。而凸模端面上的倾斜面实际也是导向面内径较小的一部分，也能在挤压的时候提供很好的导向作用，使得凸模入模十分顺畅。
脱模段是通过电化学腐蚀加工出来的，将整个毛胚凸模放入电解液中，将环状的电极片套在毛胚凸模的一端部上，电极片通电则会对毛胚凸模套有电极片的一端进行电解腐蚀，而毛胚凸模裸露在电极片外的部分则不会参与电解腐蚀保留原先的尺寸形成工作段，工作段直径要大于脱模段的直径，在入模时工作段直接与单向器壳体挤压成型其内腔，这样设计有效的减少凸模与单向器壳体之间的接触面积使得入模更加顺畅，而且等比例缩小的脱模段使得本凸模在脱模时可以很方便的取下。
在上述的一种单向器星轮滚柱室冷挤压凸模的制造方法中，所述第二步中的导向面的最小直径为单向器内的起动齿轮直径+1.5倍滚柱直径，所述导向面的最大直径为毛胚凸模的最大直径。
在上述的一种单向器星轮滚柱室冷挤压凸模的制造方法中，所述第五步中的工作段的长度为2mm-2.5mm。
在上述的一种单向器星轮滚柱室冷挤压凸模的制造方法中，所述第五步中的电极片的截面形状与线切割过后的毛胚凸模的截面形状相同，且所述电极片的截面积从一端至另一端等比例逐渐缩小，所述毛胚凸模自电极片开口较大一端伸入。
与现有技术相比，本产品的优点在于：
1、本设计的每个凸部的端面处均设置有入模导向面，在入模时凸出在本体外周上的每个凸部上的入模导向面都是直接与单向器壳体刚性接触的倾斜的入模导向面让凸部进入时所受到的阻力得到大幅度的降低，使得整个凸模阻力下降，进而凸模入模前进的十分顺畅。
2、凸模入模时是靠工作段挤压出单向器壳体的内腔，脱模段不参与挤压，这样工作段的长度远小于脱模段的长度，使得工作段与单向器壳体之间的接触更少，受到的阻力更小，则入模时更加顺畅。
3、在入模导向面上的弧面的内侧处设置凹陷部，凹陷部的底面为平面，使用本凸模冷挤压过后在单向器的内腔底部会留下凸台，由于凸台的端面为平面在凸台上放置滚柱能让滚柱正常工作，滚柱受到滚柱室内的弧面导向滚动不会掉出凸台外，本设计在保证了滚柱室内的滚柱正常安装工作的基础上，使得整个凸模入模十分顺畅。
附图说明
图1是本发明的结构示意图；
图2是本发明的俯视图；
图3是本发明在图2的A-A方向上半剖示意图；
图4是本发明在图2的B-B方向上的半剖视图。
图中，1、本体；11、工作段；12、脱模段；13、平面一；14、倾斜面；15、入模端；16、脱模端；17、中心孔；2、凸部；21、偏心弧部；211、弧面；22、限位部；23、入模导向面；24、凹陷部；241、平面二；25、弧面。
具体实施方式
以下是本发明的具体实施例并结合附图，对本发明的技术方案作进一步的描述，但本发明并不限于这些实施例。
如图1-图4所示的一种单向器星轮滚柱室冷挤压凸模及其制造方法,包括柱状的本体1，本体1中心位置具有用于与轴承固定的安装固定用的中心孔17，本体1的周向具有六个均匀分布用于挤压出滚柱室的凸部2，使得整个本体1外形看起来像六花的形状，凸部2的外侧均具有弧面211，本体1的端面为与其轴线相垂直的平面一13，本体1的入模端15的端面上位于每个凸部2处均具有倾斜的入模导向面23，入模导向面23靠近本体中心线一侧至外侧朝向脱模端16方向倾斜。每个入模导向面23上位于弧面211所在一侧均设有凹陷部24，凹陷部24的底面为平面二241且平面一13和平面二241相互平行。本设计的每个凸部2的端面处均设置有入模导向面23，在入模时凸出在本体1外周上的每个凸部2上的入模导向面23都是直接与单向器壳体刚性接触的倾斜的入模导向面23让凸部2进入时所受到的阻力得到大幅度的降低，使得整个凸模阻力下降，进而凸模入模前进的十分顺畅。在凸部2的端面上设置入模导向面23，入模导向面23是倾斜面14在挤压过后在单向器的滚柱室底部留下斜面不利于滚柱的安装，所以本设计在入模导向面23上的弧面211的内侧处设置凹陷部24，凹陷部24的底面为平面，这样在冷挤压过后在单向器的 内腔底部会留下凸台，我们只需要将滚柱放置在凸台上即可，凸台的端面为平面能让滚柱正常工作，弧面211也会在单向器内腔形成相同弧度的弧面211，滚柱受到弧面211导向滚动不会掉出凸台外，在保证了滚柱室内的滚柱正常安装工作的基础上，使得整个凸模入模十分顺畅。所有的凸部2上的入模导向面23均以本体1轴线为中心向外倾斜设置，所有的入模导向面23组合起来看起来像是一个环形的倾斜面14。让凸模的端部看起来带有一定锥度，这样的凸模端部在入模前进时相较之平面的端面所受到的阻力会大大降低，使得入模变得十分的顺畅。
本体1沿其长度方向可以分为工作段11和脱模段12，入模导向面23和凹陷部24都位于工作段11上的凸部2上，工作段11上的凸部2的外周直径保持不变，而脱模段12沿其长度方向的横截面形状都相同但是横截面的大小由靠近工作段11至远离工作段11等比例缩小。本体1在使用时是工作段11与单向器壳体直接接触挤压的，脱模段12等比例缩小在挤压时能让凸模的外周面能与单向器壳体的内腔壁的接触面积变小，接触面积变小则摩擦力也会变小，使得入模的时候更加顺畅。而且在单向器内腔挤压出成型之后脱模段12外侧面与单向器内腔壁之间会具有一定间隙，这样有利凸模的脱模，让凸模脱模也变得十分顺畅。脱模段12的长度远大于工作段11的长度。工作段11长度为2mm-2.5mm，工作段11相当于工作带的作用，实际在凸模入模时是靠工作段11挤压出单向器壳体的内腔，脱模段12不参与挤压，这样工作段11的长度远小于脱模段12的长度，使得工作段11与单向器壳体之间的接触更少，受到的阻力更小，则入模时更加顺畅。工作段11的端面上沿其周向设有环状的倾斜面14，每个入模导向面23均与倾斜面14齐平。工作段11的端面上的环形的倾斜面14的也是起到入模时起到导向的作用能有效的减少阻力， 凸部2上的入模导向面23与倾斜面14相连接且齐平，这样组合形成一个完整的导向面能让工作段11在入模的时候受到的阻力得到大大的降低，让凸模的入模变得十分顺畅。每个凸部2均包括左右两部分组成分别为偏心弧部21和限位部22，弧面211为偏心弧部21的外侧面，偏心弧部21主要是能挤压出滚柱室，滚柱室的侧面为与弧面211一样，限位部22则是能挤压出限制滚柱滚出滚柱室外的凸出限位部22的外侧面与弧面211相交处具有向内凹陷的弧面25，凹陷部24开设在偏心弧部21的端部上。凹陷部24则是只开设在偏心弧部21上让挤压出来的滚柱室的底面保持平面，而限位部22处的端面则是为倾斜的入模导向面23，让凸模入模时更加顺畅。
本设计的凸模可以通过以下方法进行生产加工：第一步，毛胚凸模准备：先对胚料的外周进行车削，然后对胚料进行热处理得到毛胚凸模；第二步，精车：使用车床对毛胚凸模的端面的外沿进行车削形成环状的导向面，导向面的倾斜角度差不多是4度；第三步，线切割：使用线切割机对毛胚凸模进行慢走丝线切割，凸部2通过线切割成型于毛胚凸模的外周，凹陷部24通过线切割成型于每个凸部2的端部上，弧面211通过线切割成型于凸部2的外侧面上，导向面通过线切割在每个凸部2处形成入模导向面23；第四步，电化学腐蚀：将毛胚凸模放入电解液中并在毛胚凸模的一端套设环状的电极片，毛胚凸模位于电极片内侧的一端通过电解腐蚀得到截面积逐渐变小的脱模段12，毛胚凸模位于电极片外的一端形成工作段11；第五步，热处理：将毛胚凸模进行热处理得到成品凸模。本设计的入模导向面23的加工需要现在毛胚凸模的端面上沿其周向切出整个环状的导向面，然后在线切割出凸部2的时候直接将导向面分割成一个个的入模导向面23，这样的加工十分方便使得本凸模在冷挤压单向器壳体时入模十分顺 畅。而凸模端面上的倾斜面14实际也是导向面内径较小的一部分，也能在挤压的时候提供很好的导向作用，使得凸模入模十分顺畅。脱模段12是通过电化学腐蚀加工出来的，将整个毛胚凸模放入电解液中，将环状的电极片套在毛胚凸模的一端部上，电极片通电则会对毛胚凸模套有电极片的一端进行电解腐蚀，而毛胚凸模裸露在电极片外的部分则不会参与电解腐蚀保留原先的尺寸形成工作段11，工作段11直径要远小于脱模段12的直径，在入模时工作段11直接与单向器壳体挤压成型其内腔，这样设计有效的减少凸模与单向器壳体之间的接触面积使得入模更加顺畅，而且等比例缩小的脱模段12使得本凸模在脱模时可以很方便的取下。第二步中的导向面的最小直径为单向器内的起动齿轮直径+1.5倍滚柱直径，导向面的最大直径为毛胚凸模的最大直径。第五步中的所使用到的电极片的截面形状也是六花形状的其最小内径比毛胚凸模的最大外径略大，而且电极片逐渐缩小，且电极片的截面积从一端至另一端等比例逐渐缩小，毛胚凸模自电极片开口较大一端伸入，通过电化学腐蚀之后毛胚凸模的一端具有7度的一个脱模角。
本文中所描述的具体实施例仅仅是对本发明精神作举例说明。本发明所属技术领域的技术人员可以对所描述的具体实施例做各种各样的修改或补充或采用类似的方式替代，但并不会偏离本发明的精神或者超越所附权利要求书所定义的范围。

Claims (10)

  1. 一种单向器星轮滚柱室冷挤压凸模,包括具有入模端(15)和脱模端(16)且呈柱状的本体(1)，所述本体(1)的周向具有若干用于挤压出滚柱室的凸部(2)，所述凸部(2)的外侧均具有弧面(211)，所述入模端(15)的端面为与本体(1)轴线相垂直的平面一(13)，其特征在于，所述凸部(2)位于入模端(15)一侧的端面上具有入模导向面(23)，所述入模导向面(23)相对平面一(13)朝向脱模端(16)方向倾斜，每个入模导向面(23)上位于弧面(211)所在一侧均设有凹陷部(24)，所述凹陷部(24)的底面为平面二(241)且平面一(13)和平面二(241)相互平行。
  2. 根据权利要求1所述的一种单向器星轮滚柱室冷挤压凸模，其特征在于，所述凸部(2)均包括偏心弧部(21)和限位部(22)，所述弧面(211)为偏心弧部(21)的外侧面，所述限位部(22)的外侧面与弧面(211)相交处具有向内凹陷的弧面(25)，所述凹陷部(24)位于偏心弧部(21)的端部上。
  3. 根据权利要求2所述的一种单向器星轮滚柱室冷挤压凸模，其特征在于，所述本体(1)沿其长度方向上可分为脱模段(12)和工作段(11)，所述本体(1)位于脱模段(12)上的径向截面面积由靠近工作段(11)一侧至背离工作段(11)一侧逐渐变小且本体(1)位于脱模段(12)上各处的径向截面的形状均相同，所述入模导向面(23)和凹陷部(24)均位于工作段(11)的本体(1)上。
  4. 根据权利要求3所述的一种单向器星轮滚柱室冷挤压凸模，其特征在于，所述脱模段(12)的长度远大于工作段(11)的长度。
  5. 根据权利要求4所述的一种单向器星轮滚柱室冷挤压凸模，其特征在于，所有的入模导向面(23)均环绕本体(1)中心线设置。
  6. 根据权利要求3或4或5所述的一种单向器星轮滚柱室冷挤压凸模，其特征在于，所述工作段(11)的端面上沿其周向设有环状的倾斜面(14)，每个入模导向面(23)均与倾斜面(14)齐平。
  7. 一种单向器星轮滚柱室冷挤压凸模的制造方法，其特征在于，本制造方法包括以下步骤：
    第一步，毛胚凸模准备：先对胚料的外周进行车削，然后对胚料进行热处理得到毛胚凸模；
    第二步，精车：使用车床对毛胚凸模的端面的外沿进行车削形成环状的导向面；
    第三步，线切割：使用线切割机对毛胚凸模进行慢走丝线切割，所述凸部(2)通过线切割成型于毛胚凸模的外周，所述凹陷部(24)通过线切割成型于每个凸部(2)的端部上，所述弧面(211)通过线切割成型于凸部(2)的外侧面上，所述导向面通过线切割在每个凸部(2)处形成入模导向面(23)；
    第四步，电化学腐蚀：将毛胚凸模放入电解液中并在毛胚凸模的一端套设环状的电极片，所述毛胚凸模位于电极片内侧的一端通过电解腐蚀得到截面积逐渐变小的脱模段(12)，所述毛胚凸模位于电极片外的一端形成工作段(11)；
    第五步，抛光：将毛胚凸模进行抛光得到成品凸模。
  8. 根据权利要求7所述的一种单向器星轮滚柱室冷挤压凸模的制造方法，其特征在于，所述第二步中的导向面的最小直径为单向器内的起动齿轮直径+1.5倍滚柱直径，所述导向面的最大直径为毛胚凸模的最大直径。
  9. 根据权利要求8所述的一种单向器星轮滚柱室冷挤压凸模的制造方法，其特征在于，所述第五步中的工作段(11)的长度为2mm-2.5mm。
  10. 根据权利要求9所述的一种单向器星轮滚柱室冷挤压凸 模的制造方法，其特征在于，所述第五步中的电极片的截面形状与线切割过后的毛胚凸模的截面形状相同，且所述电极片的截面积从一端至另一端等比例逐渐缩小，所述毛胚凸模自电极片开口较大一端伸入。
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