High-precision metal plate belt pulley pattern forming method and equipment

Abstract

The high-precision sheet metal belt pulley pattern forming method comprises the steps that S1, an embossed blank is prepared through a previous stamping procedure, the diameter of a center hole of the embossed blank is controlled to be 0.39 times of the diameter of the contour edge of a pattern petal, and the thickness of an embossed face material of the embossed blank is 0.9-1.1 times of the thickness of a raw material; s2, drawing oil is smeared on the outer diameter surface of a cylinder of the embossed blank, and oil residue cleaning is conducted on the embossed surface of the embossed blank through a surface treatment unit; according to the method, a systematic treatment scheme is achieved through a process-equipment cooperation mechanism, the causal chain of flow instability-forming rebound-outline out-of-tolerance is solved through design of the center hole diameter, the material thickness, surface treatment, positioning precision and receding, high-precision pattern forming is achieved, the requirements for 0.015 mm profile tolerance and R angle tolerance are met, and the product quality is improved. And the qualified rate of products is improved.

Description

Technical Field

[0001] The invention relates to a high-precision sheet metal pulley pattern forming method and equipment, belonging to the technical field of pulley pattern forming. Background Art

[0002] In the automotive, engineering machinery, and precision transmission system manufacturing sectors, pulley pattern forming is a core process, directly impacting transmission efficiency, noise control, and product lifespan. With increasing industry demand for lightweighting and high precision, such as the ISO10099 standard requiring a profile of ≤0.05mm, traditional stamping equipment struggles to meet the stringent tolerances of petal profiles ≤0.015mm and R0.5±0.5. Existing equipment, largely modified from general-purpose stamping platforms, lacks specialized control mechanisms for pattern forming, resulting in low yield rates for high-value-added products and an urgent need for systematic optimization.

[0003] The existing equipment does not set a 0.39 times ratio between the center hole diameter and the petal outline edge diameter, which easily causes uneven radial stress distribution of the blank material during stamping, and uncontrolled fluctuations in the thickness of the embossed surface material make the material outflow rate uncontrollable; In addition, residual stretching oil interferes with the flow characteristics, aggravating material accumulation or thinning. At the same time, the surface treatment unit lacks precise cleaning and outer diameter directional oiling, and residual stretching oil interferes with the flow characteristics, aggravating material accumulation or thinning. At the same time, due to insufficient positioning accuracy of the workbench, the embossing punch is eccentric. After the material outflow stabilizes, the embossing punch positioning ring cannot generate effective reaction force at the critical point, and the petal surface cannot be compacted and formed. The uncontrolled material flow and positioning deviation together lead to disorderly accumulation of excess material, which cannot accommodate long and short flower-shaped materials with uneven thickness, and ultimately cause the petal surface contour to be greater than 0.015mm, the total contour to be greater than 0.04mm, and the R angle size to be out of tolerance.

[0004] Due to systematic defects in the center hole diameter, material thickness, surface treatment, positioning accuracy and concession design, the existing equipment forms a causal chain of flow instability-forming rebound-contour deviation, resulting in high-precision pattern forming unable to meet the 0.015mm contour and R angle tolerance requirements, resulting in a low product qualification rate. Summary of the Invention

[0005] In view of the shortcomings of the prior art, the purpose of the present invention is to provide a high-precision sheet metal pulley pattern forming method and equipment to solve the problems of the prior art.

[0006] In order to achieve the above object, the present invention is implemented through the following technical solutions: A high-precision sheet metal pulley pattern forming method, comprising the following steps: S1 prepared by the front stamping process embossed blank, control the embossed blank center hole diameter is 0.39 times the edge diameter of the flower petal outline, the embossed blank embossed surface material thickness is 0.9-1.1 times the thickness of the raw material; S2. Apply stretching oil on the outer diameter surface of the embossed cylindrical blank, and clean the embossed surface of the embossed blank by the surface treatment unit; S3. The processed embossed blank is positioned on the workbench by a precise positioning assembly, so that the outer diameter of the embossed blank cylinder forms an interference fit of 0.05mm with the embossing punch positioning ring, ensuring that the center of the embossing punch and the center of the cylindrical blank remain concentric; S4. The embossing process is implemented by the embossing forming component, and the reaction force of the embossing punch positioning ring is used to control the outflow of material. When the outflow of material reaches an appropriate level, further outflow is prevented to ensure that the embossed petal surface is full and firm; S5. The preliminary pattern is refined through the yield grooves between the petal convex pieces in the upper module. When the embossed surface material is thick, the excess material flows into the yield grooves corresponding to the length and shape of the workpiece pattern, reducing the material rebound effect. At the same time, the holding time and unloading speed are controlled so that the pattern reaches the final stable state after elastic recovery, forming a high-precision pulley pattern finished product with a petal surface profile within 0.015mm, a total pattern surface profile within 0.04mm, and a pattern R angle of R0.5±0.5.

[0007] As a further improvement, step S1 includes: The thickness of the embossed surface end face is controlled to be 0.9-1.1 times the thickness of the raw material, and the outer diameter accuracy of the embossed blank cylinder is ensured to be within the range of ±0.02mm. The quality inspection of the prepared embossed blank is carried out, including the measurement of the center hole diameter, the thickness of the embossed surface material and the outer diameter of the cylinder.

[0008] As a further improvement, step S2 includes: Use a fiber-free wipe to thoroughly clean the embossed surface to ensure that there is no oil film residue. Apply stretching oil evenly only on the outer diameter surface of the cylinder. The oil film thickness should be controlled within the range of 0.01-0.02mm. Let it stand for 3-5 minutes to allow the oil film to be evenly distributed.

[0009] As a further improvement, step S3 includes: Place the processed blank into the embossing equipment, confirm that the outer diameter of the embossed blank cylinder forms an interference fit of 0.05mm with the embossing punch positioning ring, and verify that the center of the embossing punch is concentric with the center of the cylindrical blank, with a deviation of ≤0.02mm.

[0010] As a further improvement, step S4 includes: Set the preset pressure value according to the material thickness, control the stamping speed to 20-30mm / s, ensure the uniform flow of the material, monitor the outflow of the material, and when the outflow material reaches the preset level, the reaction force of the embossing punch positioning ring will prevent the material from flowing further.

[0011] As a further improvement, step S6 is also included: inspecting the formed pattern through a quality inspection component, with no less than 20 sampling points per petal, measuring the petal surface contour and R angle size, and ensuring that the petal surface contour is within 0.015mm, the total flower pattern surface contour is within 0.04mm, and the flower pattern R angle is R0.5±0.5.

[0012] A high-precision sheet metal pulley pattern forming device, comprising: a basic frame component, a blank pre-processing component, a precise positioning component, an embossing forming component and a quality inspection component; The basic frame assembly includes a high-rigidity bed and a working platform, and the blank pretreatment assembly includes a plurality of groups of nozzles that are lifted and lowered on the working platform and a reversible wiping mechanism that is arranged on one side of the working table; The embossing forming assembly includes an upper module, a flower-shaped petal convex piece arranged below the upper module, and a lower module installed in the middle of the workbench; The precise positioning assembly includes an embossing punch positioning ring arranged in the middle of the lower part of the upper module, a positioning block arranged in the middle of the upper part of the lower module, and a guide mechanism for controlling the vertical movement of the upper module. The embossing blank cylinder is placed on the working platform, and the positioning block is inserted into the middle of the lower part of the embossing blank cylinder. During embossing, the embossing punch positioning ring is inserted into the middle of the upper part of the embossing blank cylinder, and the flower petal convex pieces are pressed against the upper surface of the embossing blank cylinder. The precise positioning assembly and the embossing forming assembly work together to ensure the concentricity of the center of the embossing blank and the center of the flower petal outline through the embossing punch positioning ring, forcing the upper module to extrude material evenly outward during the embossing process. When the outflow material reaches a preset level, the outflow material flow of the embossing surface is increased by the reaction force of the embossing punch positioning ring, thereby preventing the material from further outflow, thereby ensuring that the embossed petal surface is full and firm. By making way for the flower groove to accommodate excess material according to the thickness of the embossing surface material, the rebound of the flower surface forming is reduced, and high-precision flower pattern forming is achieved with a petal surface contour within 0.015mm, a total flower surface contour within 0.04mm, and a flower pattern R angle of R0.5±0.5.

[0013] As a further improvement, the blank pretreatment component includes an annular groove arranged on the working platform, a ring body embedded in the annular groove, a first electric guide rod for controlling the lifting of the ring body, and a nozzle embedded in several of the ring bodies. The nozzle of the nozzle is opened on the inner side of the ring body, and an oil film is sprayed on the outer ring surface of the embossed blank cylinder through cooperation with the ring body, the first electric guide rod and the nozzle.

[0014] As a further improvement, the wiping mechanism includes a scrubbing assembly rotatably mounted on one side of the working platform, the scrubbing assembly includes a second electric guide rod rotatably mounted on one side of the working platform, a fixed plate fixedly mounted on the top of the electric guide rod, a scrubbing disk rotatably arranged on the fixed plate toward the side of the working platform, and a first motor that drives the scrubbing disk to rotate, a second motor mounted below the side of the working platform, and the second motor drives the second electric guide rod to rotate.

[0015] As a further improvement, a support strip is spirally installed on the surface of the scrubbing disc from the inside out, an absorbent sheet is covered on the outer surface of the support strip, and a scrubbing cloth is covered on the outer surface of the absorbent sheet, the support strip is made of silicone material, the absorbent sheet is made of sponge material, and the scrubbing cloth is made of non-woven material; The spiral installation direction of the support bar is consistent with the rotation direction of the scrubbing disc, and the oil on the upper surface of the embossed blank cylinder can be wiped from the inside to the outside.

[0016] The beneficial effects of the present invention are: The present invention realizes a systematic treatment solution through a process-equipment synergy mechanism. By precisely setting the diameter of the center hole to 0.39 times the diameter of the edge of the petal contour, the radial stress of the blank is forced to be evenly distributed, eliminating the material thickness fluctuation caused by uneven stress, and strictly controlling it to 0.9-1.1 times the thickness of the raw material, so that the material outflow rate is stabilized within the process critical point. Directed oil film control is used in the surface treatment process: the embossed surface is thoroughly cleaned by the wiping mechanism, and the non-woven fabric-covered scrubbing disk is used to wipe it spirally from the inside to the outside to ensure that there is no stretching oil residue; at the same time, the blank pretreatment component forms a uniform oil film only on the outer diameter of the cylinder through the lifting of the ring body and the inner nozzle, accurately controlling the material flow characteristics and avoiding accumulation or thinning caused by traditional uneven coating.

[0017] The precise positioning assembly, driven by the closed-loop control of the guide mechanism's servo hydraulic cylinder and proportional flow valve, ensures absolute concentricity between the blank and the punch when the upper module presses vertically downward. During the embossing process, the petal fins squeeze the blank. When the material flows out evenly to a critical point, the reaction force of the embossing punch's locating ring suddenly increases, instantly locking out excessive outflow and ensuring a full and firm petal surface. The lower module's integrated flower groove dynamically adjusts to the thickness difference between long and short flower patterns, orderly accommodating excess material and reducing forming rebound stress by over 40%. This allows for direct adherence to the stringent tolerances of petal surface profile ≤0.015mm, total profile ≤0.04mm, and R angle R0.5±0.5.

[0018] In addition, in order to address the systematic defects of existing equipment such as material flow instability, positioning deviation and contour rebound caused by uncontrolled center hole diameter, the integrated design accurately cuts off the causal chain of flow instability-forming rebound-contour deviation, achieving high-precision forming of petal surface contour ≤0.015mm, total contour ≤0.04mm and R angle R0.5±0.5.

[0019] In order to fundamentally solve the problems of uncontrolled center hole diameter and unstable material flow, it is required that when preparing the blank in the previous process, the center hole diameter must be precisely controlled to 0.39 times the diameter of the petal contour edge, ensuring that the inner diameter of the blank cylinder and the embossed punch positioning ring and positioning block of the precise positioning component form a 0.05mm interference fit.

[0020] Force the center of the blank to be concentric with the pattern contour to eliminate uneven radial stress caused by eccentricity; At the same time, the blank pretreatment component uses a lifting nozzle to thoroughly remove the residual stretching oil on the embossed surface, and uses a reversible wiping mechanism to apply stretching oil only on the outer diameter of the cylinder, accurately controlling the material outflow rate and avoiding flow instability caused by thickness fluctuations (0.9-1.1 times the thickness of the raw material).

[0021] During the embossing process, the upper die is pressed vertically downward by a guide mechanism. The embossing punch's retaining ring and positioning block are simultaneously inserted into the blank cylinder. A 0.05mm interference fit ensures concentricity of ≤0.01mm. As the flower petals press against the blank, material flows evenly to a critical point. The reaction force of the embossing punch's retaining ring increases sharply, instantly suppressing excessive outflow and ensuring a full, firm petal surface. This eliminates the material accumulation or thinning caused by loose positioning in existing equipment.

[0022] The lower module integrates a recessed groove, whose mold surface precisely matches the contours of long and short flower patterns, dynamically accommodating excess material with uneven embossed thickness. This design reduces forming rebound stress by over 40% through orderly material diversion, ensuring a stable petal profile within 0.015mm and precise R angle formation within the R0.5±0.5 tolerance range, completely resolving the contour distortion caused by insufficient recess in existing technologies.

[0023] The embossed blank is placed on the work platform, and the blank pretreatment assembly is activated. The nozzle rises and falls to spray detergent to remove oil from the embossed surface. The wiping mechanism flips, applying stretching oil only to the outer diameter of the cylinder. The blank is lowered onto the positioning block, and the upper module lowers to insert the embossing punch positioning ring above the blank. The 0.05mm interference fit automatically corrects concentricity. The upper module continues to press down, squeezing the flower petals and convex parts of the blank, ensuring a uniform outflow of material. When the outflow reaches a critical point, the reaction force of the embossing punch positioning ring locks the outflow, allowing the flower groove to simultaneously absorb excess material. The quality inspection component scans the flower contour in real time and feeds data back to the control system to ensure that the R angle and contour accuracy meet standards.

[0024] By adjusting the center hole diameter, material thickness, surface treatment, positioning accuracy and clearance design, the causal chain of flow instability-forming rebound-contour deviation is solved, so that high-precision pattern forming can meet the 0.015mm contour and R angle tolerance requirements, thereby improving the low product qualification rate. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments. It should be understood that the following drawings only illustrate certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other relevant drawings can be obtained based on these drawings without paying any creative work.

[0026] Figure 1 This is a step diagram of a high-precision sheet metal pulley pattern forming method of the present invention.

[0027] Figure 2 It is a three-dimensional structural schematic diagram of a high-precision sheet metal pulley pattern forming device of the present invention.

[0028] Figure 3 It is a partially enlarged structural schematic diagram of a high-precision sheet metal pulley pattern forming device of the present invention.

[0029] Figure 4 This is a schematic diagram of the main structure of a high-precision sheet metal pulley pattern forming method and equipment of the present invention.

[0030] Figure 5 yes Figure 3 The middle enlarged part is a schematic diagram of the ring structure in the raised state.

[0031] Figure 6 It is a schematic diagram of the cross-sectional structure of the bottom of a scrubbing plate and a partially enlarged support strip, an absorbent sheet, and a scrubbing cloth of the present invention.

[0032] Figure 7 It is a structural schematic diagram of an embossing forming component of the present invention.

[0033] Figure 8 It is a structural schematic diagram of a long and short flower-shaped cylindrical workpiece of the present invention.

[0034] Figure 9 It is a structural schematic diagram of a uniform flower-shaped cylindrical workpiece of the present invention.

[0035] Figure 10 This is a module connection diagram of a high-precision sheet metal pulley pattern forming device of the present invention.

[0036] 1. Basic frame assembly; 2. Blank pretreatment assembly; 3. Precision positioning assembly; 4. Embossing forming assembly; 5. Quality inspection assembly; 6. Embossing blank cylinder; 7. Control module; 8. Limit module; 9. Injection module; 11. High rigidity bed; 12. Working platform; 21. Nozzle; 22. Ring groove; 23. Ring body; 24. First electric guide rod; 25. Second electric guide rod; 26. Fixing plate; 27. Scrubbing disc; 28. First motor; 29. ​​Second motor; 271. Support bar; 272. Absorbent sheet; 273. Scrubbing cloth; 31. Embossing punch positioning ring; 32. Positioning block; 33. Hydraulic press; 34. Output head; 41. Upper module; 42. Flower petal convex piece; 43. Lower module; 51. Conveyor belt; 52. Arch frame; 53. Detection sensor; 61. Long and short flower-shaped cylindrical workpieces; 62. Uniform flower-shaped cylindrical workpieces; 63. Give way flower troughs. DETAILED DESCRIPTION

[0037] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention. Therefore, the following detailed description of the embodiments of the present invention provided in the drawings is not intended to limit the scope of the invention for which protection is sought, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0038] In the description of the present invention, the terms first and second are used for descriptive purposes only and should not be understood to indicate or imply relative importance or implicitly specify the number of the technical features indicated. Therefore, features defined as first or second may explicitly or implicitly include one or more of the features. In the description of the present invention, the meaning of "plurality" is two or more, unless otherwise specifically defined.

[0039] Reference Figure 1 As shown, a high-precision sheet metal pulley pattern forming method comprises the following steps: S1 prepared by the front stamping process embossed blank, control the embossed blank center hole diameter is 0.39 times the edge diameter of the flower petal outline, the embossed blank embossed surface material thickness is 0.9-1.1 times the thickness of the raw material; Among them, the raw materials specifically refer to unprocessed metal sheets. In the previous stamping process, the metal sheets are stamped into cylindrical blanks. During this process, due to the flow and deformation of the material, the material thickness of the embossed surface will vary slightly from the thickness of the original metal sheet, but it must be strictly controlled within the range of 0.9-1.1 times the thickness of the original sheet.

[0040] S2. The embossed surface of the embossed blank is cleaned by the surface treatment unit to ensure that there is no residual stretching oil on the embossed surface. At the same time, stretching oil is applied only on the outer diameter surface of the embossed blank cylinder 6 to control the flow characteristics of the material during the embossing process. S3. The processed embossed blank is positioned on the work platform 12 by the precise positioning assembly 3, so that the outer diameter of the embossed blank cylinder 6 forms an interference fit of 0.05mm with the embossing punch positioning ring 31, ensuring that the center of the embossing punch remains concentric with the center of the cylindrical blank; S4 embossing process is implemented by the embossing forming assembly 4, using the reaction force of the embossing punch positioning ring 31 to control the outflow of material, and when the outflow of material reaches an appropriate level, further outflow is prevented to ensure that the embossed petal surface is full and firm; Among them, the embossing punch is controlled to move downward to extrude the blank material, so that the material flows outward evenly under the action of the embossing punch. When the outflow of material reaches a critical point, the reaction force generated by the embossing punch positioning ring 31 increases and prevents the material from flowing out further, forming a preliminary pattern outline. At the same time, the embossing depth and pressure distribution are controlled to ensure that the R angles at the top and bottom of the pattern are initially formed. S5. By controlling the thickness of the embossed surface material to have a thicker length and short pattern, excess material is accommodated through the yielding grooves 63 between the flower pattern petal lobes in the upper module 41, so that the yielding grooves on the upper module 41 correspond to the length and short flower patterns of the workpiece, thereby facilitating the flow of excess material to the yielding grooves and reducing the rebound of the flower pattern surface during forming, and ultimately achieving high-precision flower pattern forming with a petal surface contour within 0.015mm, a total flower pattern surface contour within 0.04mm, and a flower pattern R angle of R0.5±0.5.

[0041] Existing equipment causes a causal chain of flow instability, forming rebound, and contour deviation due to out-of-control center hole diameter, material thickness fluctuation, surface treatment failure, positioning deviation, and insufficient clearance.

[0042] A systematic cure is achieved through a process-equipment synergy mechanism. The core is to accurately set the diameter of the center hole to 0.39 times the diameter of the petal outline edge, forcing the radial stress of the blank to be evenly distributed, eliminating the material thickness fluctuation caused by uneven stress, and strictly controlling it to 0.9-1.1 times the thickness of the raw material, so that the material outflow rate is stable within the process critical point. Directed oil film control is used in the surface treatment process: the embossed surface is thoroughly cleaned by the wiping mechanism, and the non-woven fabric-covered scrubbing disk 27 is used to wipe it from the inside out in a spiral to ensure that there is no residual stretching oil; At the same time, the blank pretreatment component 2 forms a uniform oil film only on the outer diameter of the cylinder through the lifting of the ring body 23 and the inner nozzle 21, accurately controlling the flow characteristics of the material and avoiding accumulation or thinning caused by traditional uneven coating.

[0043] The precise positioning assembly 3, through a 0.05mm interference fit between the embossing punch locating ring 31 and the positioning block 32, is driven by the closed-loop control of the guide mechanism's servo hydraulic cylinder and the proportional flow valve. This ensures that the blank and the punch are absolutely concentric when the upper module 41 presses vertically downward. During the embossing forming stage, the flower petal protrusions 42 squeeze the blank. When the material flows out evenly to a critical point, the reaction force of the embossing punch locating ring 31 suddenly increases, instantly locking out excessive outflow and ensuring the fullness and firmness of the petal surface. The lower module 43 integrates a recessed groove that dynamically matches the thickness difference of long and short flower patterns, orderly accommodating excess material and reducing forming rebound stress by over 40%. This directly achieves the strict tolerances of petal surface profile ≤0.015mm, total profile ≤0.04mm, and R angle R0.5±0.5.

[0044] The center hole diameter and material thickness are controlled by S1 through the previous process; the embossed blank is placed on the working platform 12, the wiping mechanism rotates the scrubbing disc 27 to remove oil stains on the embossed surface, and the blank pretreatment component 2 ring body 23 descends and sprays the outer diameter oil film in a directional manner.

[0045] The blank is lowered to the positioning block 32, and the upper module 41 is pressed vertically downward by the hydraulic press 33. The embossing punch positioning ring 31 forms an interference fit of 0.05mm with the blank; when the flower-shaped petal protrusion 42 is squeezed, the material flows out to the critical point and is suppressed by the reaction force of the positioning ring, making way for the flower groove to absorb the excess material synchronously.

[0046] The conveyor belt 51 transports the workpiece, and the laser profiler detects the contour and R angle in real time. The data is fed back to the control system to eliminate abnormal products.

[0047] This process completely cuts off the vicious cycle of center hole out of control - material thickness fluctuation - outflow instability - positioning deviation - contour deviation, improves the material flow control accuracy by 50%, and ensures that the yield of high value-added products is stable at more than 98%.

[0048] The concentricity error is controlled within 0.01mm through a 0.05mm interference fit and reaction force mechanism. Combined with the stress release effect of the yielding flower groove, the petal surface contour is stabilized within 0.015mm (6 times better than the ISO 10099 standard), and the R angle tolerance is compressed to R0.5±0.5, completely avoiding dimensional failure caused by positioning drift and rebound in existing technologies.

[0049] By precisely controlling the directional oil film and material thickness to eliminate flow interference, the single-piece molding cycle is shortened by 20%; the high-rigidity bed 11 and the hydraulic closed-loop system suppress vibration, enabling high-precision patterns to be produced without manual intervention in the mass production of high-end transmission components such as new energy vehicles.

[0050] Compared with existing technologies, it abandons the extensive transformation logic of general platforms and uses the three-in-one mechanism of stress uniformization, flow precision and rebound suppression to transform multi-link defects into a controllable process chain to meet the industry bottleneck demand of 0.015mm contour.

[0051] Step S1 includes: S11. Measure the diameter of the petal outline of the flower, typically 42.1 mm. S12. Calculate the center hole diameter of the embossed blank: flower petal outline edge diameter × 0.39. For a flower petal outline edge diameter of 42.1mm, the center hole diameter is 16.5mm. S13. Producing cylindrical blanks through the previous stamping process; S14. Strictly control the thickness of the embossed surface to be 0.9-1.1 times the thickness of the raw material; S15. Ensure that the outer diameter accuracy of the embossed blank cylinder 6 is within the range of ±0.02mm; S16. Perform quality inspection on the prepared embossed blank, including measurement of the center hole diameter, embossed surface material thickness and cylinder outer diameter.

[0052] In step S12, if the diameter of the center hole is too large, the resistance to material flow toward the center is small during the stamping process, and the petal surface contour and the pattern R angle are both unqualified; if the diameter of the center hole is too small, the resistance to material flow toward the center increases, and after the pattern is formed, the rebound amount of the pattern surface contour increases, and the pattern surface contour is unqualified.

[0053] In step S14, when the thickness of the raw material is relatively thick, after the flower pattern is extruded, the stress of the flower petals is released and rebounds, resulting in unqualified flower pattern surface contour, and the extrusion flower pattern mold is subjected to large force and the mold life is short; when the thickness of the raw material is relatively thin, the volume of material required for forming the flower pattern is insufficient, the R angle at the top of the flower pattern is not fully formed, the R angle size exceeds the tolerance and is unqualified, the flower pattern petal surface is weak, and the single-side contour and the total surface contour of the flower pattern petals are unqualified.

[0054] Step S2 includes: S21. Use a lint-free cloth to thoroughly clean the embossed surface, ensuring that no oil film remains. S22. Apply stretching oil evenly only on the outer diameter surface of the cylinder, and control the oil film thickness within the range of 0.01-0.02mm; S23. Let it stand for 3-5 minutes to allow the oil film to be evenly distributed.

[0055] In step S21, when there is a stretching oil film on the embossed surface of the blank, the friction coefficient of the embossing punch when extruding the material will be reduced during the forming process, the radial flow resistance of the material along the embossed surface will be small, and the inward flow of the material will increase, resulting in a weak embossed surface, an incomplete R angle of the pattern, and unqualified surface contour and R angle.

[0056] Step S3 includes: S31. The processed blank is placed into the embossing equipment; S32 confirms that the outer diameter of the embossed blank cylinder 6 forms an interference fit of 0.05mm with the embossing punch positioning ring 31; S33. Verify that the center of the embossing punch is concentric with the center of the cylindrical blank, with a deviation of ≤0.02mm.

[0057] The interference in step S32 is 0.05mm. Too small an interference is not conducive to providing resistance to prevent material outflow. Too large an interference will cause large external tension on the embossing punch positioning ring 31, shorten the mold life, increase the rebound amount of the flower petal surface, and cause the surface contour to be unqualified.

[0058] Step S4 includes: S41. Set the preset pressure value according to the material thickness; S42. Control the punching speed to 20-30 mm / s to ensure uniform material flow; S43. Monitor the outflow of material. When the outflow reaches a preset level, the reaction force of the embossing punch positioning ring 31 is used to prevent further outflow of the material.

[0059] S44: Release the pressure slowly, control the unloading speed to ≤10mm / s, and use the stretching oil on the outer diameter of the cylinder to assist in demoulding and reduce surface damage.

[0060] Step S5 includes: S51. Determine whether the thickness of the embossed surface material exceeds the standard value; S52. When the material thickness exceeds the standard value, the die surface is processed to give way to the workpiece pattern corresponding to the flower groove; S53. Accurately control the depth of the flower groove to ensure that excess material can flow in smoothly and reduce the rebound of the flower surface during forming.

[0061] In step S52, the yielding flower groove is formed according to the length and short pattern, and the yielding flower groove of the mold corresponds to the length and short pattern of the workpiece pattern.

[0062] S6: The formed pattern is inspected by the quality inspection component 5, with no less than 20 sampling points per petal, and the petal surface contour and R angle dimensions are measured to ensure that the petal surface contour is within 0.015mm, the total pattern surface contour is within 0.04mm, and the pattern R angle is R0.5±0.5.

[0063] Reference Figure 2-10 As shown, a high-precision sheet metal pulley pattern forming device includes: a basic frame component 1, a blank pre-processing component 2, a precise positioning component 3, an embossing forming component 4 and a quality inspection component 5; The basic frame assembly 1 includes a high-rigidity bed 11 and a work platform 12, and the blank pretreatment assembly 2 includes a plurality of nozzles 21 that are lifted and lowered on the work platform 12 and a reversible wiping mechanism that is arranged on one side of the work platform; The embossing forming assembly 4 includes an upper module 41, a flower-shaped petal convex piece 42 arranged below the upper module 41, and a lower module 43 installed in the middle of the workbench; The precise positioning assembly 3 includes an embossing punch positioning ring 31 provided in the middle of the lower portion of the upper module 41, a positioning block 32 provided in the middle of the upper portion of the lower module 43, and a guide mechanism for controlling the vertical movement of the upper module 41. The embossing blank cylinder 6 is placed on the working platform 12, and the positioning block 32 is inserted into the middle of the lower portion of the embossing blank cylinder 6. During embossing, the embossing punch positioning ring 31 is inserted into the middle of the upper portion of the embossing blank cylinder 6, and the flower petal protrusion 42 presses the upper surface of the embossing blank cylinder 6. The outer diameters of the embossing punch positioning ring 31 and the positioning block 32 form an interference fit of 0.05 mm with the inner diameter of the embossing blank cylinder 6; The precise positioning assembly 3 and the embossing forming assembly 4 work together to ensure the concentricity of the center of the embossed blank and the center of the flower petal outline through the embossing punch positioning ring 31, forcing the upper module to extrude material evenly outward during the embossing process. When the outflow material reaches a preset level, the outflow material flow of the embossed surface is increased by the reaction force of the embossing punch positioning ring 31, thereby preventing the material from further outflow, thereby ensuring that the embossed petal surface is full and firm. By making way for the flower groove to accommodate excess material according to the thickness of the embossing surface material, the rebound of the pattern surface forming is reduced.

[0064] This enables high-precision flower pattern forming with a petal surface contour within 0.015mm, a total flower pattern surface contour within 0.04mm, and a flower pattern R angle of R0.5±0.5.

[0065] The processed embossed blank cylinder 6 includes a long and short patterned cylindrical workpiece or a uniform patterned cylindrical workpiece.

[0066] In response to the systematic defects of existing equipment such as material flow instability, positioning deviation and contour rebound caused by uncontrolled center hole diameter, the integrated design accurately cuts off the causal chain of flow instability-forming rebound-contour deviation, achieving high-precision forming with petal surface contour ≤0.015mm, total contour ≤0.04mm and R angle R0.5±0.5.

[0067] In order to fundamentally solve the problem of uncontrolled center hole diameter and unstable material flow, it is required that when preparing the blank in the previous process, the center hole diameter must be accurately controlled to 0.39 times the diameter of the petal contour edge to ensure that the inner diameter of the blank cylinder and the embossing punch positioning ring 31 and positioning block 32 of the precise positioning component 3 form a 0.05mm interference fit.

[0068] Force the center of the blank to be concentric with the pattern contour to eliminate uneven radial stress caused by eccentricity; At the same time, the blank pretreatment component 2 thoroughly removes the residual stretching oil on the embossed surface through the lifting nozzle 21, and uses a reversible wiping mechanism to apply stretching oil only on the outer diameter of the cylinder, accurately controlling the material outflow rate to avoid flow instability caused by thickness fluctuations (0.9-1.1 times the thickness of the raw material).

[0069] During the embossing process, the upper die block 41 is pressed vertically downward under the control of a guide mechanism. The embossing punch retaining ring 31 and positioning block 32 are simultaneously inserted into the blank cylinder. A 0.05mm interference fit ensures concentricity of ≤0.01mm. As the flower petal protrusions 42 press against the blank, the material flows out evenly to a critical point. The reaction force of the embossing punch retaining ring 31 suddenly increases, instantly suppressing excessive outflow and ensuring a full, firm petal surface. This eliminates the material accumulation or thinning caused by loose positioning in existing equipment.

[0070] The lower module 43 integrates a recessed groove, whose mold surface precisely matches the contours of the long and short flower patterns, dynamically accommodating excess material with uneven thickness on the embossed surface. This design reduces forming rebound stress by over 40% by orderly diverting material, ensuring a stable petal profile within 0.015mm and precise R angle formation within the R0.5±0.5 tolerance range, completely resolving the contour distortion caused by insufficient recess in existing technologies.

[0071] The embossed blank is placed on the working platform 12, the blank pretreatment component 2 is started, the nozzle 21 is raised and lowered to spray the cleaning agent to remove the oil on the embossed surface, and the wiping mechanism is turned over to apply the stretching oil only on the outer diameter of the cylinder.

[0072] The blank is lowered to the positioning block 32, and the upper module 41 is lowered so that the embossing punch positioning ring 31 is inserted above the blank, and the 0.05mm interference fit automatically corrects the concentricity.

[0073] The upper module 41 continues to press down, the flower-shaped petal convex piece 42 squeezes the blank, and the material flows out evenly; when the outflow reaches a critical point, the reaction force of the embossing punch positioning ring 31 locks the outflow, making way for the flower groove to absorb the excess material synchronously.

[0074] The quality inspection component 5 scans the pattern contour in real time and feeds back the data to the control system to ensure that the R angle and contour meet the standards.

[0075] Through the three-in-one design breakthrough of precise positioning, controllable flow and dynamic concession, the material outflow control accuracy is improved by 50% through interference fit and reaction force mechanism, eliminating the chain reaction of flow instability, and increasing the yield of high value-added products to more than 98% (existing equipment is generally less than 85%).

[0076] The yielding flower groove and thickness adaptation design suppress the forming rebound within 0.005mm, directly achieving the ISO 10099 out-of-tolerance standard and breaking the industry's 0.05mm bottleneck.

[0077] Vibration is suppressed by the high-rigidity bed 11 of the basic frame, and the blank pretreatment is linked with the embossing forming component 4 to reduce manual intervention. The single-piece forming cycle is shortened by 20%, making it suitable for mass production of high-end transmission components such as new energy vehicles.

[0078] Existing equipment lacks the ability to coordinate center hole control, surface treatment orientation, and dynamic yielding, resulting in uncontrollable material flow and positioning drift, forming a vicious cycle; Through the 0.05mm interference fit of the precise positioning component 3, the critical reaction force mechanism of the embossing punch positioning ring 31, and the intelligent diversion of the yielding flower groove, multi-link problems are transformed into a systematic solution, which not only eliminates contour deviations and R angle failures, but also improves the overall accuracy by more than 3 times.

[0079] The blank pretreatment component 2 includes an annular groove 22 arranged on the working platform 12, a ring body 23 embedded in the annular groove 22, and a first electric guide rod 24 for controlling the lifting and lowering of the ring body 23. The nozzle 21 is embedded in several of the ring bodies 23. The nozzle of the nozzle 21 is opened on the inner side of the ring body 23. The oil film is sprayed on the outer ring surface of the embossed blank cylinder 6 through the cooperation of the ring body 23, the first electric guide rod 24 and the nozzle 21.

[0080] The blank pretreatment component 2 adopts an integrated structure of an annular groove 22, a ring body 23 and a first electric guide rod 24, aiming to solve the problem of material flow instability caused by inaccurate application of stretching oil in existing equipment.

[0081] In traditional processes, stretching oil easily remains on the embossed surface or is unevenly applied to the outer diameter, interfering with the uniform outflow of the material during the embossing process, causing petal profile deviations and R-angle distortion. This assembly, with its ring body 23 embedded in the annular groove 22 of the work platform 12, is driven up and down by a first electric guide rod 24, ensuring that the nozzle of the nozzle head 21 embedded in the ring body 23 is precisely aligned with the outer surface of the embossed blank cylinder 6.

[0082] During operation, the ring body 23 descends to the height of the outer diameter of the blank, and the nozzle 21 sprays the stretching oil film from the inner side surface in a directional manner, covering only the outer surface of the cylinder to prevent the oil from contacting the embossed surface; The ring 23 then rises and resets. This mechanism ensures that the embossed surface is completely free of oil residue (in conjunction with the previous cleaning step), while the outer diameter oil film thickness is uniform and controllable, strictly limiting the material flow range.

[0083] Furthermore, by improving the stretching oil application accuracy to the micron level, radial stress fluctuations caused by oil film interference are eliminated, and the material outflow rate is stabilized within the critical point required by the process, directly supporting high-precision forming of the petal surface contour of ≤0.015mm, avoiding contour rebound and dimensional failure caused by application deviation in existing technologies.

[0084] The wiping mechanism includes a scrubbing assembly rotatably mounted on one side of the working platform 12, and the scrubbing assembly includes a second electric guide rod 25 rotatably mounted on one side of the working platform 12, a fixed plate 26 fixedly mounted on the top of the electric guide rod, a scrubbing disc 27 rotatably arranged on the fixed plate 26 toward the side of the working platform 12, and a first motor 28 that drives the scrubbing disc 27 to rotate, and a second motor 29 mounted below the side of the working platform 12, and the second motor 29 drives the second electric guide rod 25 to rotate.

[0085] The surface of the scrubbing plate 27 is spirally installed with a support bar 271 from the inside out, an absorbent sheet 272 is covered on the outer surface of the support bar 271, and a scrubbing cloth 273 is covered on the outer surface of the absorbent sheet 272. The support bar 271 is made of silicone material, the absorbent sheet 272 is made of sponge material, and the scrubbing cloth 273 is made of non-woven material.

[0086] The spiral installation direction of the support bar 271 is consistent with the rotation direction of the scrubbing disc 27, and the oil on the upper surface of the embossing blank cylinder 6 can be wiped from the inside to the outside.

[0087] The wiping mechanism solves the problem of material flow interference caused by residual stretching oil on the embossed surface through the cooperation of the second electric guide rod 25 and the rotating scrubbing disk 27.

[0088] Traditional cleaning methods are prone to leaving oil film or damaging the surface due to disordered wiping direction or insufficient material adaptation, causing fluctuations in the material outflow rate during the embossing process, resulting in excessive petal contour and R angle deformation.

[0089] By using the second motor 29 to drive the second electric guide rod 25 to rotate, the scrubbing assembly is precisely positioned above the embossed blank cylinder 6; after the first motor 28 is started, the scrubbing disc 27 rotates at high speed in the spiral direction, and its silicone support strips 271 (the spiral direction is consistent with the rotation direction) guide the oil stains on the embossed surface to migrate from the inside to the outside, the sponge absorption sheet 272 efficiently absorbs the residual oil, and the non-woven scrubbing cloth 273 achieves traceless cleaning.

[0090] During operation, the scrubbing disc 27 gently presses the upper surface of the blank. As it rotates, oil contaminants are systematically directed to the edges, ensuring the embossed surface is absolutely free of oil residue and preventing surface scratches. This mechanism improves cleaning precision to the micron level, eliminating the interference of oil contaminants on the material's radial stress, ensuring a stable and controllable material outflow rate during the embossing process, and directly ensuring the required petal surface profile of ≤0.015mm, avoiding the risk of contour rebound and dimensional failure caused by cleaning failure in existing technologies.

[0091] The quality inspection component 5 includes a conveyor belt 51 installed on one side of the working platform 12, an arch frame 52 installed on the high-rigidity bed 11 above the conveyor belt 51, and a detection sensor 53 arranged in the middle below the arch frame 52. The embossed surface of the embossed blank cylinder 6 on the conveyor belt 51 is detected by the detection sensor 53.

[0092] The guide mechanism includes a hydraulic press 33 installed on the high-rigidity bed 11 and an output head 34 installed at the output end of the hydraulic press 33. The upper module 41 is fixedly installed below the output head 34 by bolts, and the upper module 41 is controlled to move up and down by the hydraulic press 33.

[0093] The detection sensor 53 of the quality detection component 5 can be a high-precision laser profiler or a machine vision system. The laser profiler obtains the 3D topography data of the embossed surface in real time through non-contact scanning, with a measurement accuracy of ±0.005mm, and directly verifies the compliance of the petal profile ≤0.015mm and the R angle R0.5±0.5; The machine vision system utilizes a high-resolution industrial camera coupled with sub-pixel image processing algorithms to dynamically identify surface oil residue and contour distortion. Both are integrated beneath the arch 52 and move synchronously with the conveyor 51 to perform in-line inspection, ensuring that defective products are immediately rejected and preventing contour rebound caused by flow instability.

[0094] The hydraulic press 33 of the guide mechanism consists of a servo hydraulic cylinder, a proportional flow valve, and a closed-loop pressure control system. The servo hydraulic cylinder provides high-rigidity vertical thrust, while the proportional flow valve precisely regulates the oil flow rate to achieve micron-level control of the upper die block 41's lifting and lowering speed (±0.01mm positioning accuracy). The closed-loop system compensates for load fluctuations in real time, ensuring the stability of the 0.05mm interference fit between the embossing punch locating ring 31 and the blank cylinder. This mechanism effectively suppresses vibration interference associated with traditional mechanical guides and ensures precise triggering of the reaction force at the critical point of material outflow.

[0095] The above-mentioned sensors and hydraulic systems are mature technologies in the industrial field. Their selection and parameter configuration comply with ISO10099 and JIS B 6402 standards, and no additional explanation of the specific implementation details is required.

[0096] The control module 7 , the limit module 8 , and the oil injection module 9 are electrically connected to the first motor 28 , the second motor 29 , the electric guide rod, the limit module 8 , the first electric guide rod 24 , the second electric guide rod 25 , the oil injection module 9 , and the hydraulic press 33 .

[0097] The limit module 8, integrated into the motion control system, monitors the travel of key components in real time via high-precision displacement sensors and electronic limit switches. During the raising and lowering phases of the ring body 23, the limit module 8 sets a 0.05mm threshold to ensure accurate positioning of the ring body 23 at the blank's outer diameter, preventing overtravel and oil film spray offset. During the descent of the scrubbing plate 27, the module monitors the vertical displacement of the fixed plate 26 and limits the descent depth to 0.1mm to prevent excessive pressure from the scrubbing cloth 273 and damage to the embossed surface. When the upper module 41 presses downward, the limit module 8, in conjunction with the hydraulic press 33, precisely controls the embossing depth to the critical point for round-angle formation (0.5±0.02mm) and locks the hold time to eliminate petal contour distortion caused by uncontrolled travel. This module limits mechanical motion errors to within ±0.01mm, providing the foundation for a 0.05mm interference fit and a profile accuracy of 0.015mm.

[0098] The fuel injection module 9 adopts a closed-loop pressure control system, which consists of a proportional flow valve and a micro pressure sensor (not shown) to dynamically adjust the injection volume (0.15-0.25ml / cm2) and injection pressure (0.3-0.4MPa).

[0099] The module uses a solenoid valve to control the start and stop of the spray nozzle 21 with a response time of ≤5ms, ensuring that the stretching oil is sprayed only on the outer diameter of the cylinder, forming a uniform oil film of 0.02mm thickness. This precise control eliminates fluctuations in oil film thickness (±0.005mm) and strictly limits the material outflow rate to within the critical process range, preventing material accumulation due to oil overload or thinning caused by insufficient oil flow. This directly supports the required petal surface profile of ≤0.015mm. The module works in conjunction with the limiter mechanism to achieve micron-level stability in the surface treatment process, fundamentally addressing the flow instability caused by oil film interference in existing technologies.

[0100] The embossed blank cylinder 6 is placed on a workbench and positioned with the positioning block 32. The control module 7 cooperates with the first electric guide rod 24 to control the ring body 23 to rise. This, in conjunction with the oil spray module 9, sprays an oil film on the outer annular surface of the embossed blank cylinder 6 and then resets. The oil spray module 9 primarily controls the oil injection volume and pressure, while the control module 7 controls the opening and closing of the nozzle 21. This opening and closing function is achieved by providing a solenoid valve, which is a prior art feature and will not be described in detail.

[0101] After the oil film is sprayed on the outer annular surface of the embossed blank cylinder 6, the control module 7 cooperates with the second motor 29 to control the second electric guide rod 25 to rotate 90°. The second electric guide rod 25 controls the fixing plate 26 to descend, so that the scrubbing cloth 273 contacts the upper surface of the embossed blank cylinder 6, and the scrubbing disc 27 is driven by the first motor 28 to rotate and scrub, and then reset.

[0102] The control module 7 cooperates with the hydraulic press 33 to control the upper module 41 to be pressed downward toward the lower module 43, and the embossing punch positioning ring 31 cooperates with the middle part of the embossing blank cylinder 6 for secondary positioning, and then the flower-shaped petal protrusion 42 presses the embossed surface of the upper surface of the flower blank cylinder 6 into shape, maintains the pressure for a preset time, and then resets.

[0103] The embossed blank cylinder 6 is placed on the conveyor belt 51 and passes through the detection sensor 53 to complete the acceptance.

[0104] The embossing punch positioning ring 31 is made of Cr12MoV die steel with a heat treatment hardness of HRC58-60, an inner diameter tolerance controlled at -0.005~0mm, a surface roughness of Ra0.2μm, and forms an accurate 0.05mm interference fit with the outer diameter of the embossing blank cylinder 6.

[0105] It should be noted that the device structure and drawings of the present invention mainly describe the principles of the present invention. In terms of the technology of the design principle, the settings of the device's power mechanism, power supply system, and control system are not fully described. However, those skilled in the art can clearly understand the details of its power mechanism, power supply system, and control system on the premise that they understand the principles of the above invention. The control method of the application document is automatic control through a controller, and the control circuit of the controller can be implemented by simple programming by those skilled in the art. The standard parts used can be purchased from the market and can be customized according to the description in the specification and drawings. The specific connection methods of each part adopt conventional means such as mature bolts, rivets, welding, etc. in the existing technology. The machinery, parts and equipment all adopt conventional models in the existing technology, and the components known to technical personnel in this field, their structures and principles can be known to these technical personnel through technical manuals or through conventional experimental methods.

[0106] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. A high-precision sheet metal pulley pattern forming method, characterized in that: The steps include: S1 prepared by the front stamping process embossed blank, control the embossed blank center hole diameter is 0.39 times the edge diameter of the flower petal outline, the embossed blank embossed surface material thickness is 0.9-1.1 times the thickness of the raw material; S2. Apply stretching oil to the outer diameter surface of the embossed blank cylinder (6), and clean the embossed surface of the embossed blank with oil residue through the surface treatment unit; S3. Position the processed embossed blank on the workbench through the precise positioning assembly (3), so that the outer diameter of the embossed blank cylinder (6) and the embossing punch positioning ring (31) form a 0.05mm interference fit, ensuring that the center of the embossing punch and the center of the cylindrical blank remain concentric; S4. The embossing process is implemented by the embossing forming assembly (4), and the reaction force of the embossing punch positioning ring (31) is used to control the outflow of the material. When the outflow of the material reaches an appropriate level, further outflow is prevented to ensure that the embossed petal surface is full and firm; S5. The preliminary pattern is refined by the yielding groove (63) between the petal convex pieces of the upper module (41). When the thickness of the embossed surface material is thick, the excess material flows into the yielding groove (63) corresponding to the length and shortness of the workpiece pattern, reducing the material rebound effect. At the same time, the holding time and the unloading speed are controlled so that the pattern reaches the final stable state after elastic recovery, forming a high-precision pulley pattern finished product with a petal surface profile within 0.015mm, a total pattern surface profile within 0.04mm, and a pattern R angle R0.5±0.

5.

2. A high-precision sheet metal pulley pattern forming method according to claim 1, characterized in that: Step S1 includes: The thickness of the embossed surface end face is controlled to be 0.9-1.1 times the thickness of the raw material, ensuring that the outer diameter accuracy of the embossed blank cylinder (6) is within the range of ±0.02mm. The quality inspection of the prepared embossed blank is carried out, including the measurement of the center hole diameter, the thickness of the embossed surface material and the outer diameter of the cylinder.

3. A high-precision sheet metal pulley pattern forming method according to claim 1, characterized in that: Step S2 includes: Use a fiber-free wipe to thoroughly clean the embossed surface to ensure that there is no oil film residue. Apply stretching oil evenly only on the outer diameter surface of the cylinder. The oil film thickness should be controlled within the range of 0.01-0.02mm. Let it stand for 3-5 minutes to allow the oil film to be evenly distributed.

4. A high-precision sheet metal pulley pattern forming method according to claim 1, characterized in that: Step S3 includes: Place the processed blank into the embossing equipment, confirm that the outer diameter of the embossed blank cylinder (6) forms an interference fit of 0.05mm with the embossing punch positioning ring (31), and verify that the center of the embossing punch and the center of the cylinder blank are concentric, with a deviation of ≤0.02mm.

5. A high-precision sheet metal pulley pattern forming method according to claim 1, characterized in that: Step S4 includes: The preset pressure value is set according to the material thickness, and the punching speed is controlled to 20-30 mm / s to ensure uniform material flow. The material outflow is monitored. When the outflow material reaches a preset level, the reaction force of the embossing punch positioning ring (31) is used to prevent the material from further outflow.

6. A high-precision sheet metal pulley pattern forming method according to claim 1, characterized in that: The process also includes step S6: inspecting the formed pattern through the quality inspection component (5), sampling at no less than 20 points per petal, measuring the petal surface contour and R angle dimensions, and ensuring that the petal surface contour is within 0.015 mm, the total pattern surface contour is within 0.04 mm, and the pattern R angle is R0.5±0.

5.

7. A high-precision sheet metal pulley pattern forming device, using a high-precision sheet metal pulley pattern forming method according to any one of claims 1 to 6, characterized in that: include: Basic frame assembly (1), blank pre-processing assembly (2), precise positioning assembly (3), embossing forming assembly (4) and quality inspection assembly (5); The basic frame assembly (1) includes a high-rigidity bed (11) and a work platform (12), and the blank pretreatment assembly (2) includes a plurality of groups of nozzles (21) that are lifted and arranged on the work platform (12) and a reversible wiping mechanism that is arranged on one side of the work platform; The embossing forming assembly (4) comprises an upper module (41), a flower-shaped petal convex piece (42) arranged below the upper module (41), and a lower module (43) installed in the middle of the workbench; The precise positioning component (3) includes an embossing punch positioning ring (31) arranged in the middle of the lower part of the upper module (41), a positioning block (32) arranged in the middle of the upper part of the lower module (43), and a guide mechanism for controlling the upper module (41) to move in the vertical direction. The embossing blank cylinder (6) is placed on the working platform (12), and the positioning block (32) is inserted into the middle of the lower part of the embossing blank cylinder (6). During embossing, the embossing punch positioning ring (31) is inserted into the middle of the upper part of the embossing blank cylinder (6), and the flower petal protrusion (42) squeezes the upper surface of the embossing blank cylinder (6); The precise positioning component (3) and the embossing forming component (4) work in coordination to ensure the concentricity of the center of the embossed blank and the center of the flower petal outline through the embossing punch positioning ring (31), forcing the upper module (41) to extrude the material to flow outward uniformly during the embossing process. When the outflow material reaches a preset level, the outflow material flow of the embossed surface is increased by the reaction force of the embossing punch positioning ring (31), thereby preventing the material from further outflow, thereby ensuring that the embossed petal surface is full and firm. By making way for the flower groove (63) to accommodate excess material according to the thickness of the embossed surface material, the rebound of the flower pattern surface forming is reduced, and high-precision flower pattern forming is achieved, with a petal surface contour within 0.015 mm, a total flower pattern surface contour within 0.04 mm, and a flower pattern R angle R0.5±0.

5.

8. The high-precision sheet metal pulley pattern forming equipment according to claim 7, characterized in that: The blank pretreatment component (2) includes an annular groove (22) provided on the working platform (12), a ring body (23) embedded in the annular groove (22), and a first electric guide rod (24) for controlling the lifting and lowering of the ring body (23). A nozzle (21) is embedded in a plurality of the annular bodies (23). The nozzle of the nozzle (21) is opened on the inner side surface of the annular body (23). The oil film is sprayed on the outer annular surface of the embossed blank cylinder (6) through the cooperation of the annular body (23), the first electric guide rod (24) and the nozzle (21).

9. The high-precision sheet metal pulley pattern forming equipment according to claim 8, characterized in that: The wiping mechanism includes a scrubbing assembly rotatably mounted on one side of the working platform (12), the scrubbing assembly including a second electric guide rod (25) rotatably mounted on one side of the working platform (12), a fixed plate (26) fixedly mounted on the top end of the electric guide rod, a scrubbing disc (27) rotatably arranged on the fixed plate (26) toward the side of the working platform (12), and a first motor (28) for driving the scrubbing disc (27) to rotate, and a second motor (29) mounted below the side of the working platform (12), wherein the second motor (29) drives the second electric guide rod (25) to rotate.

10. The high-precision sheet metal pulley pattern forming equipment according to claim 9, characterized in that: A support strip (271) is spirally mounted on the surface of the scrubbing disc (27) from the inside out, an absorbent sheet (272) is coated on the outer surface of the support strip (271), and a scrubbing cloth (273) is coated on the outer surface of the absorbent sheet (272), wherein the support strip (271) is made of a silicone material, the absorbent sheet (272) is made of a sponge material, and the scrubbing cloth (273) is made of a non-woven material; The spiral installation direction of the support bar (271) is consistent with the rotation direction of the scrubbing disc (27), and the oil on the upper surface of the embossed blank cylinder (6) can be wiped from the inside to the outside.

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