A one-piece spun pulley forming process
The integral spinning pulley forming process solves the problem of forming annular bosses in spinning pulleys, realizing efficient and energy-saving spinning pulley manufacturing with good strength, material saving, simple process and low cost.
Patent Information
- Application Number
- CN202211358583.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- Filing Date
- 2022-11-01
- Publication Date
- 2025-12-12
- Estimated Expiration
- 2042-11-01
AI Technical Summary
Existing technologies make it difficult to efficiently form the annular boss of the spun pulley, especially when the boss is thickened in the middle, due to material limitations. Furthermore, the welding method leads to part deformation and low precision, resulting in complex processes and high costs.
The integral spinning pulley forming process includes blanking, deep drawing, shaving the boss, shaping, edge machining, spinning the pulley groove and finishing, forming an annular boss and retaining upper and lower reinforcing grooves around it to avoid welding and achieve integral forming.
It achieves efficient forming of spinning pulleys, resulting in high strength, material savings, shorter processes, and high manufacturing efficiency. It also avoids deformation and precision problems caused by welding, thus reducing costs.
Smart Images
Figure CN115990764B_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application belongs to the technical field of automobile parts manufacturing, and particularly relates to a forming process of a hub pulley. BACKGROUND
[0002] According to the use requirements, it is often necessary to make a hub at the center of the spinning pulley. The shape of the hub is a ring-shaped boss, which is used for fixing or mounting parts. Due to the limitation of materials, the material needs to be thickened in the middle part. It is difficult to achieve by ordinary processing methods. The commonly used process is to use multiple deep drawing and step-by-step pulling up, or to pull up a relatively short boss by overall thinning of the material. The process is often complicated or cannot meet the functional requirements. Once the bottom of the boss is a closed structure or has a convex edge towards the center, it cannot be achieved by stamping. Another way is to weld a boss at the part where the boss is needed. However, welding is easy to cause deformation of the part, and the process is unstable. Figure 1 As shown in the figure, the boss is welded. Since there is no positioning point inside and outside the boss, it is not easy to position when welding the boss. A ring-shaped groove 14 needs to be machined on the pulley body before welding the boss. When welding, the boss is installed in the groove, and the boss needs to be ensured to be concentric with the center hole. Since the inner sink 13 needs to install parts, the outer circle 12 of the boss is the positioning of another part, so after welding, neither the boss nor the part is allowed to have a protruding weld, and the part precision requirement is high. Therefore, after welding, the part must be finished, and the protruding weld and the deformation caused by welding must be removed. The manufacturing process is complex and the cost is high. SUMMARY
[0003] The purpose of the present application is to overcome the above-mentioned deficiencies of the prior art and provide a whole spinning pulley forming process. The forming process is short, easy to process, high in manufacturing efficiency, and the formed pulley is a whole without welding, good in strength.
[0004] The technical solution adopted by the present application is as follows: a whole spinning pulley forming process, the forming process steps are as follows:
[0005] 1) blanking: the steel plate or steel belt is cut into a circular blank by stamping or laser cutting; the thickness of the blank is T;
[0006] 2) deep drawing: the circular blank is stretched into a cylindrical blank by deep drawing process;
[0007] 3) shovel spinning boss: starting from the appropriate starting position a of the upper surface of the cylindrical blank, spinning the local material under the action of pressure to flow from the four sides to the center part, and at the same time, the local material is upwardly protruded to form a required ring-shaped boss, and an upper groove with a finishing allowance is formed between the position a and the ring-shaped boss; the width of the upper groove is W; the depth Du of the upper groove is less than or equal to 0.5T;
[0008] 4) Shaping: the blank after step 3) spinning is placed on an oil press or punch to shape the upper groove part and form the upper and lower reinforcing grooves; the upper reinforcing groove is located on the upper surface of the blank, and the lower reinforcing groove is located on the lower surface of the blank;
[0009] The notch width of the upper reinforcing groove is Wu; Wu: W = 0.4~0.5:1; the depth of the upper reinforcing groove is Du; the depth of the lower reinforcing groove Dd is less than or equal to 0.5T;
[0010] The minimum distance S between the inner wall of the upper reinforcing groove and the inner wall of the lower reinforcing groove is greater than or equal to 0.5T;
[0011] 5) Turning: the blank after step 4) shaping is placed on a lathe to turn the lower end surface of the blank to make the lower end surface parallel to the upper end surface;
[0012] 6) Spinning pulley groove: the blank after step 5) turning is placed on a spinning machine to spin and form a pulley groove on the outer circumferential wall;
[0013] 7) Finishing turning: the excess amount reserved in step 3) spinning and the burr generated in step 6) are finished to form a semi-finished pulley;
[0014] 8) Machining mounting hole: the semi-finished pulley after step 7) finishing turning is placed on a punching device to machine mounting holes and / or boss center holes.
[0015] The step 8) is: the semi-finished pulley after step 7) finishing turning is placed on a punching device to machine mounting holes and boss center holes; the boss center hole is a through hole.
[0016] The step 8) is: the semi-finished pulley after step 7) finishing turning is placed on a punching device to machine mounting holes and boss center holes; the boss center hole is a counterbore hole.
[0017] In step 3), a finishing allowance of 0.5~1mm is reserved when spinning and forming the annular boss.
[0018] The center axis of the annular boss coincides with the center axis of the cylindrical blank.
[0019] The center axis of the upper reinforcing groove coincides with the center axis of the annular boss.
[0020] The center axis of the lower reinforcing groove coincides with the center axis of the upper reinforcing groove 2.
[0021] The upper reinforcing groove has an arc-shaped cross-section; the lower reinforcing groove has an arc-shaped cross-section; the inner diameter of the upper reinforcing groove is smaller than the inner diameter of the lower reinforcing groove; the outer diameter of the upper reinforcing groove is larger than the inner diameter of the lower reinforcing groove but smaller than the outer diameter of the lower reinforcing groove.
[0022] The ratio (G / r) between the outer edge of the lower reinforcing groove and the distance G between the mounting hole and the mounting hole radius r is not less than 0.8.
[0023] Another objective of this invention is to provide a pulley manufactured using the aforementioned integral spinning pulley forming process.
[0024] The advantages of this invention are as follows: The integral spinning pulley forming process provided by this invention is applicable to spinning pulleys or other components with similar structures. The part has an annular boss in the middle, with a countersunk hole, blind hole, or through hole in the center. Traditional machining methods cannot produce this type of pulley. This process uses spinning to process the boss, retaining two annular reinforcing grooves formed by spinning at the upper and lower ends around the boss. This saves material and enhances strength. After processing, the material thickness of the inner and outer surfaces remains unchanged except for the material thickness inside the boss in the groove area and the material thickness at the mounting holes where bolts need to be installed. Furthermore, the two end faces inside the boss and the two end faces outside the lower reinforcing groove are on the same plane. This allows locking parts to be installed using either the center hole inside the hub or the mounting holes on the outer ring. This process makes the spinning pulley integrally formed, resulting in high strength, short forming steps, easy processing, high manufacturing efficiency, energy conservation and emission reduction, and material savings. Attached Figure Description
[0025] Figure 1 This is a schematic diagram of the existing technology.
[0026] Figure 2 This is a schematic diagram of the process of the present invention.
[0027] Figure 3 This is a schematic diagram of the structure of a pulley manufactured using the present invention.
[0028] Figure 4 This is the second schematic diagram of the pulley manufactured using the present invention.
[0029] Figure 5 This is the third schematic diagram of the structure of the pulley manufactured using the present invention.
[0030] In the figure, 1 is an annular boss, 2 is an upper reinforcing groove, 3 is a lower reinforcing groove, 4 is a centrally protruding edge, 5 is a mounting hole, 6 is a through hole, 7 is a wave-shaped structure, 8 is a wheel rim, 9 is a wheel spoke, 10 is a pulley groove, 11 is a countersunk hole, 12 is the outer circle of the boss, 13 is the countersunk inside the boss, and 14 is a groove for fixing the boss. DETAILED DESCRIPTION
[0031] As shown in the figure, the forming process of the integral spinning pulley provided by the present application is as follows: Figure 2
[0032] 1) blanking: the steel plate or steel belt is cut into a circular blank by punching or laser cutting; the thickness of the blank is T.
[0033] 2) drawing: the circular blank can be pre-formed into a cylindrical blank due to its large diameter. The drawing process is used to stretch the circular blank into a cylindrical blank.
[0034] 3) shovel spinning boss: starting from the appropriate starting position a in the middle of the upper surface of the cylindrical blank, spinning is performed to make the local material flow from the periphery to the center under the action of pressure, and at the same time, the required annular boss is formed by protruding upward, and an annular upper groove with a finishing allowance is formed between position a and the annular boss. Since the annular boss requires high precision, a certain finishing allowance needs to be left, and the allowance generally needs to be more than 0.5, which can be adjusted according to the precision of the equipment. The slot width of the upper groove is W, and the depth Du of the upper groove is equal to 0.5T. The starting position a can be calculated by CAD volume calculation according to the volume of the material contained in the upper groove part being equal to the volume of the required formed boss part.
[0035] 4) shaping: the blank after step 3) spinning is placed on an oil press or punch, and the upper groove part from the lower surface of the blank is shaped to form the upper reinforcing groove 2 and the lower reinforcing groove 3 of the finished product. The lower reinforcing groove 3 needs to avoid the mounting hole 5 and reserve enough pressure surface for the mounting bolt of the mounting hole 5. The upper reinforcing groove 2 is located on the upper surface of the blank, and the lower reinforcing groove 3 is located on the lower surface of the blank.
[0036] The slot width of the upper reinforcing groove 2 is Wu; Wu: W = 0.5:1; the depth of the upper reinforcing groove 2 is Du; the depth Dd of the lower reinforcing groove 3 is equal to 0.5T. The minimum distance S between the inner wall of the upper reinforcing groove 2 and the inner wall of the lower reinforcing groove 3 is equal to 0.5T. The ratio G / r of the distance G between the outer edge of the lower reinforcing groove 3 and the mounting hole and the radius r of the mounting hole is equal to 0.9.
[0037] 5) turning: the blank after step 4) shaping is placed on a lathe to turn the lower end surface of the blank to make the lower end surface parallel to the upper end surface. Due to the anisotropy of the material and the drawing positioning problem in step 2) drawing, the height of the port b is not uniform, so turning is used to turn the position to make the height of the part uniform.
[0038] 6) spinning pulley groove: the blank after step 5) turning is placed on a spinning machine to spin and form the pulley groove on the outer circumferential wall.
[0039] 7) Finishing: The allowance reserved during spinning in step 3) and the flash generated in step 6) on the blank are finished to form a semi-finished pulley.
[0040] 8) Machining mounting holes: Place the semi-finished pulley after precision machining in step 7) on a punching machine to machine mounting holes and boss center holes.
[0041] Once the entire pulley part is formed and machined, rust-proof surface treatment can be applied as needed.
[0042] Figure 3 This is an integrally spun pulley manufactured using the above-described process, comprising an integrally spun rim 8, spokes 9, and a hub. The hub is an annular boss 1 protruding upwards from the center of the spokes. The central axis of the annular boss coincides with the central axis of the spokes. A countersunk hole 11 is provided inside the hub. Near the hub, the spokes 9 have a wavy structure 7, composed of an annular upper reinforcing groove 2 and an annular lower reinforcing groove 3 formed during the hub spinning process. The upper reinforcing groove 2 is located on the upper surface of the spokes 9. The lower reinforcing groove 3 is located on the lower surface of the spokes 9. The cross-sections of both the upper and lower reinforcing grooves are arc-shaped. The inner diameter of the upper reinforcing groove 2 is smaller than the inner diameter of the lower reinforcing groove 3, and the outer diameter of the upper reinforcing groove 2 is larger than the inner diameter of the lower reinforcing groove 3 but smaller than its outer diameter. The central axis of the upper reinforcing groove 2 coincides with the central axis of the annular boss 1. The central axis of the lower reinforcing groove 3 coincides with the central axis of the upper reinforcing groove 2. Multiple mounting holes 5 are evenly distributed on the spokes 9. The outer wall of the rim 8 is provided with a spun pulley groove 10 (V-groove).
[0043] The pulley manufactured according to this invention has a structure in which the pulley body is on the periphery, and a boss 1 is located at the center. The boss has a recessed hole 11 inside. Spinning reduces the material around the boss 1. To meet the functional requirements of this pulley, upper reinforcing grooves 2 and lower reinforcing grooves 3 are formed on the two end faces around the boss 1 (the upper and lower reinforcing grooves 2 and 3 are achieved by stamping). The thickness of the bottom of the recessed hole (the centrally protruding edge 4) is the same as the thickness of the pulley body material. The interior of the boss can also be a blind hole (e.g., ...). Figure 4 ) or through holes (such as Figure 5 The entire part is molded in one piece, which shortens the process, saves materials, has good strength, and is highly efficient in production.
[0044] Figure 4 Another type of integral spun pulley manufactured using the above process has a blind hole inside its annular boss 1.
[0045] Figure 5 Another integral spun pulley manufactured using the above process has a through hole 6 inside its annular boss 1.
Claims
1. A one-piece spun pulley forming process characterized by: The forming processing steps are as follows: 1) blanking: the steel plate or steel strip is cut into a circular blank by punching or laser cutting; the thickness of the blank is T; 2) deep drawing: the circular blank is stretched into a cylindrical blank by deep drawing process; 3) shovel spinning boss: starting from the appropriate starting position a in the middle of the upper end surface of the cylindrical blank, spinning is carried out, so that the local material flows from the periphery to the center under the action of pressure, and at the same time, it is raised upwards to form the required annular boss, and an annular upper groove with finishing allowance is formed between position a and the annular boss; the slot width of the upper groove is W; the depth Du of the upper groove is less than or equal to 0.5T; 4) shaping: the blank after spinning in step 3) is placed on an oil press or punch, the upper groove part is shaped, and upper and lower reinforcing grooves are formed; the upper reinforcing groove is located on the upper surface of the blank, and the lower reinforcing groove is located on the lower surface of the blank; the lower reinforcing groove avoids the mounting hole and reserves enough pressing plane for the mounting hole to install the mounting bolt; the slot width of the upper reinforcing groove is Wu; Wu: W = 0.4~0.5:1; the depth of the upper reinforcing groove is Du; the depth of the lower reinforcing groove Dd is less than or equal to 0.5T; the minimum distance S between the inner wall of the upper reinforcing groove and the inner wall of the lower reinforcing groove is greater than or equal to 0.5T; the ratio (G / r) of the distance G between the outer edge of the lower reinforcing groove and the mounting hole and the radius r of the mounting hole is not less than 0.8; 5) turning edge: the blank after shaping in step 4) is placed on a lathe to turn the lower end surface of the blank, so that the lower end surface is parallel to the upper end surface; 6) spinning pulley groove: the blank after turning in step 5) is placed on a spinning machine to spin and form a pulley groove on the outer circumferential wall; 7) finish turning: the excess amount reserved on the blank in step 3) spinning and the burr generated in step 6) are finished to form a semi-finished pulley; 8) processing mounting hole: the semi-finished pulley after finish turning in step 7) is placed on a punching equipment to process mounting hole and / or boss center hole; after processing, the material thickness of the inner and outer surfaces except the groove part and the material thickness of the mounting hole where the bolt is needed is unchanged and not thinned.
2. The one-piece spun belt pulley forming process of claim 1, wherein: The step 8) is: the semi-finished pulley after finish turning in step 7) is placed on a punching equipment to process mounting hole and boss center hole; the boss center hole is a through hole.
3. The one-piece spun belt pulley forming process of claim 1, wherein: The step 8) is: the semi-finished pulley after finish turning in step 7) is placed on a punching equipment to process mounting hole and boss center hole; the boss center hole is a counterbore hole.
4. The one-piece spun belt pulley forming process of claim 1, wherein: In step 3), the spinning annular boss reserves a finishing allowance of 0.5~1mm.
5. The one-piece spun belt pulley forming process of claim 1, wherein: The center axis of the annular boss coincides with the center axis of the cylindrical blank.
6. The one-piece spun-aluminum pulley forming process of claim 1 or 5, wherein: The center axis of the upper reinforcing groove coincides with the center axis of the annular boss.
7. The one-piece spun-aluminum pulley forming process of claim 6, wherein: The center axis of the lower reinforcing groove coincides with the center axis of the upper reinforcing groove.
8. The one-piece spun belt pulley forming process of claim 1, wherein: The cross section of the upper reinforcing groove is arc-shaped; the cross section of the lower reinforcing groove is arc-shaped; the inner diameter of the upper reinforcing groove is smaller than the inner diameter of the lower reinforcing groove; the outer diameter of the upper reinforcing groove is greater than the inner diameter of the lower reinforcing groove and smaller than the outer diameter of the lower reinforcing groove.
9. A pulley manufactured by a forming process using the one-piece spun pulley of any one of claims 1-8.
Citation Information
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