Machining process for manufacturing two-stage multi-wedge-groove composite spinning belt pulley with timing signal

Abstract

A machining process for manufacturing a double-stage multi-wedge-groove composite spinning belt pulley with a timing signal comprises the steps of blanking, drawing forming, shaping, edge turning, spinning forming, mounting hole punching, leveling and timing hole punching, the double-stage multi-wedge-groove composite spinning belt pulley can be provided with double-stage multi-wedge grooves and timing signal teeth, light-weight design is achieved, the production cost is reduced, and the production efficiency is improved. And the technical problem that locking cannot be achieved due to split type installation is solved, and the competitiveness of products is improved. By means of the machining technology, it is guaranteed that the signal teeth of the timing signal panel are formed according to requirements, the sensor normally detects signals, and it is guaranteed that the timing signal electronic fuel injection system accurately controls the fuel injection amount.

Description

Technical Field

[0001] This invention belongs to the field of automobile engine crankshaft pulleys, and relates to the production process of a two-stage multi-wedge groove composite spinning pulley with timing signal. Background Technology

[0002] Spin forming technology can produce integral thin-walled parts. In the front-end gear train of an automobile engine, in addition to the pulleys used for gear train transmission, a timing device is also required. This device is used to adjust the timing signal during assembly to ensure the engine's firing order is correct. The timing device is usually replaced by a timing signal disc. During engine assembly, the spin-formed pulley and the timing disc are stacked together and locked onto the engine's crankshaft. Sensors read the timing signal disc signal to ensure the normal operation of the entire system. The spin-formed pulley, through the wound belt, can drive all the gear train components at the front of the engine to operate normally, including the water pump pulley, fan pulley, air conditioning pulley, motor pulley, etc.

[0003] Traditionally, the spinning pulley and timing signal disc mounted on the engine are manufactured separately. After each individual component is completed, they are stacked together during engine assembly. Because both components are coated with electrophoretic paint for rust prevention, each part has two mounting surfaces coated with electrophoretic paint. When the two parts are stacked together, there are four mounting surfaces coated with electrophoretic paint. This can lead to problems such as insufficient bolt torque during assembly, resulting in failure to tighten the bolts, or the bolts loosening after the engine has been running for a period of time. When the spinning pulley and timing signal disc are made into separate units, there are also issues with accumulated assembly tolerances during assembly, causing engine vibration and abnormal noise. Furthermore, manufacturing the two components separately and producing separate blanks results in a huge waste of raw materials, and the parts are relatively heavy, which contradicts the national development strategy. Summary of the Invention

[0004] This invention provides a manufacturing process for a double-stage multi-ribbed groove composite spinning pulley with timing signal. It not only solves the problem that the spinning pulley and timing signal disc cannot be locked when installed as single units overlapping each other, but also solves the problems of vibration and noise caused by the accumulation of installation tolerances and waste of raw materials. By integrating the timing signal teeth and the double-stage multi-ribbed groove pulley into a single part, it can not only achieve double-stage transmission but also ensure the timing signal. It realizes a multi-functional and lightweight design, thereby enhancing the competitiveness of the product.

[0005] The technical solution of this invention is: a manufacturing process for a two-stage multi-wedge groove composite spinning pulley with timing signal, comprising the following steps:

[0006] Hot-rolled steel plates of thickness d are cut into round discs.

[0007] The circular disc is drawn into a shape to obtain a shaped raw material. The shaped raw material includes an mounting plate and a cylindrical wall extending along the axial direction. The end of the cylindrical wall has an end arc with a radius of R1.

[0008] The end of the shaping material is shaped to obtain the edge material. The edge material includes a frustum-shaped brim located at the end. The outer surface of the longitudinal section of the frustum-shaped brim is an inclined plane. The angle between the inclined plane and the horizontal plane is α. The frustum-shaped brim is connected to the cylinder wall by a rounded corner. The radius of the arc between the outer wall of the cylinder wall and the inclined plane is R2, where R1 > R2.

[0009] The outer rim and rough edges of the frustum-shaped brim are machined to a smooth finish. Both the top and bottom of the machined surface M2 need to be chamfered and deburred to obtain the spinning raw material.

[0010] The spinning raw material is positioned and pressed by the spinning die of the spinning equipment. After the spinning equipment is closed and before spinning, the upper surface M1 of the spinning raw material mounting plate is positioned by the upper core die. The circumferential direction of the machined surface M3 of the frustum-shaped brim of the spinning raw material is positioned by the outer wall of the limiting groove on the lower core die. The outer wall of the limiting groove is clearance-fitted with the machined surface of the frustum-shaped brim before spinning. The inner wall of the limiting groove is connected to the positioning inclined surface. The inner side of the inner surface M2 of the frustum-shaped brim of the spinning raw material is fitted and positioned with the positioning inclined surface. The outer side of the inner surface of the frustum-shaped brim of the spinning raw material is suspended above the limiting groove; ensuring the spinning of the raw material... The material is aligned with the center of the spinning die and spun. A double-stage multi-wedge groove is then machined on the outer wall of the spun raw material to obtain the raw material for punching mounting holes. After machining the mounting holes on the mounting plate of the raw material for punching mounting holes, the frustum-shaped brim is leveled to form a flat brim. A timing hole is punched at the edge of the flat brim. The diameter of the outer wall of the limiting groove is 0.2-0.3 mm larger than the diameter of the machined surface of the frustum-shaped brim before spinning. The bottom of the limiting groove is at least 2 mm deeper than the lower surface of the frustum-shaped brim. The width of the limiting groove is no greater than half the length of the positioning inclined surface. The outer wall of the limiting groove is H higher than the inner wall of the limiting groove, where H = the thickness d of the hot-rolled steel plate.

[0011] The spinning die includes an upper core die and a lower core die. An ejector is inserted into the inner hole of the lower core die. The lower core die is a stepped cylinder, including a small cylinder for forming the inner wall of the spinning raw material cylinder and a large cylinder connected to the lower part of the small cylinder. A connecting surface is provided at the connection between the small cylinder and the large cylinder. The connecting surface includes a forming surface located at the upper part for forming the end of the spun product and a positioning inclined surface connected to the lower end of the forming surface for positioning the inner surface of the frustum-shaped brim before spinning. A material limiting groove is provided on the upper end surface of the large cylinder of the lower core die.

[0012] Four sets of rotating wheels feed and extrude the raw material in sequence. The four sets of rotating wheels are the edge rolling wheel, the flat spinning wheel, the pre-forming wheel, and the forming wheel.

[0013] The entire longitudinal section of the rolled edge wheel is composed of several small segments connected sequentially. These segments include circular arcs and straight lines. Each segment is labeled from bottom to top as: a1, a2, a3, a4, a5, a6, a7, a8, a9, a10, a11, a12, a13. Here, a1 is a straight line segment with an angle of 20°±10′ to the horizontal plane, a2 is a circular arc with a radius of R2±0.05, a3 is a circular arc with a radius of R2±0.05, and a... 4 is an arc with a radius of 2 ± 0.05, a5 is a vertical line segment, a6 is an arc with a radius of 2 ± 0.05, a7 is an arc with a radius of 10 ± 0.05, a8 is an arc with a radius of 2 ± 0.05, a9 is a vertical line segment, a10 is an arc with a radius of 5 ± 0.05, a11 is an arc with a radius of 26 ± 0.05, a12 is an arc with a radius of 2 ± 0.05, and a13 is a straight line segment with an angle of 20° ± 10′ to the horizontal plane.

[0014] The entire longitudinal section of the flat-rotating wheel is composed of several small segments connected in sequence. The small segments include circular arcs and straight lines. Each small segment is marked from bottom to top as: b1, b2, b3, b4, b5, b6, b7, b8, b9, b10, b11, b12, b13, b14. Among them, b1 is a straight line segment with an angle of 20°±10′ with the horizontal plane, b2 to b5 are circular arcs with R1±0.05, b6 is a circular arc with R1.5±0.05, b7 is a circular arc with R1±0.05, b8 is a circular arc with R9±0.05, b9 is a circular arc with R1±0.05, b10 is a circular arc with R1.5±0.05, b11 to b13 are circular arcs with R1±0.05, and b14 is a straight line segment with an angle of 20°±10′ with the horizontal plane.

[0015] Spinning includes the following steps:

[0016] First, the curling wheel is rotated and moved horizontally to extrude the spun material outward along the upper arc a11 of the curling wheel, the spun material outward along the middle arc a7 of the curling wheel, and the spun material forms the lower positioning teeth for positioning the belt along the lower arcs a1-a4 of the curling wheel, and the top arcs a12 and a13 form the upper positioning teeth for positioning the belt.

[0017] Then, the flat spinning wheel is rotated and moved horizontally to compress the spun material, causing it to bulge outward along the upper arc a11 of the flat spinning wheel, and the spun material continues to bulge outward along the middle arc b8 of the flat spinning wheel. The spun material continues to form positioning teeth for the positioning belt along the lower arc b1-b4 of the flat spinning wheel, and the top arc b12 to b14 continues to form upper positioning teeth for the positioning belt.

[0018] The raw material for punching mounting holes is placed into the die for punching mounting holes, and the mounting holes on the mounting plate are machined to obtain the leveling raw material. The leveling raw material is placed into the leveling die, and the frustum-shaped cap at the end of the part is machined into a horizontal state to obtain the raw material for punching timing holes. The raw material for punching timing holes is placed into the die for punching timing holes, and the timing holes of the part are machined to read the timing signal after the engine is assembled. The timing signal teeth are evenly distributed, and two teeth are removed at a specified angle to form a notch, which is used for the engine sensor to identify the timing signal. Finally, it is machined into a double-stage multi-wedge groove composite spinning pulley with timing signal and N signal teeth on the outer circle of the end.

[0019] The mounting holes include a center hole for center positioning on the engine, six bolt holes for tightening bolts on the engine, and a pin hole for angular positioning when mounted on the engine.

[0020] The mounting plate is connected to the cylinder wall via a groove; the groove includes a circular arc 1 at the position, a circular arc 2 connected to the inner end of the circular arc 1, and a circular arc 3 connected to the outer end of the circular arc 1, wherein the radius of the circular arc 1 is greater than the radius of the circular arc 2, which is greater than the radius of the circular arc 3.

[0021] The spinning machine requires a main cylinder pressure of 13-16 MPa and a side cylinder pressure of 13-16 MPa. The main cylinder rapid traverse speed is 35 mm / s-40 mm / s, and the working feed speed is 4 mm / s-8 mm / s. The edge curling wheel rapid traverse speed is 35 mm / s-40 mm / s, and the working feed speed is 2.0 mm / s-2.5 mm / s. The flat spinning wheel rapid traverse speed is 35 mm / s-40 mm / s, and the working feed speed is 0.6 mm / s-1.2 mm / s. The preforming wheel rapid traverse speed is 35 mm / s-40 mm / s, and the working feed speed is 0.6 mm / s-1.2 mm / s. The forming wheel rapid traverse speed is 35 mm / s-40 mm / s, and the working feed speed is 0.5 mm / s-1.0 mm / s.

[0022] After spinning, the deformation of the toothed wall thickness is 30%-35% compared with the thickness of the hot-rolled steel plate.

[0023] The thickness of hot-rolled steel plates is 4.5-5.0 mm.

[0024] A double-stage multi-ribbed groove composite spinning pulley with timing signal is produced by a manufacturing process for a double-stage multi-ribbed groove composite spinning pulley with timing signal.

[0025] This invention patent enables products with dual-stage multi-wedge grooves and integrated timing signal teeth, achieving a lightweight design and solving the technical problem of inability to lock in split installations, thus enhancing product competitiveness. Because the end face of the composite spinning pulley in this invention is an open structure, insufficient material stock during spinning due to the open structure of the raw material end face will cause difficulties in subsequent timing signal tooth processing. Using the processing technology of this invention ensures that the signal teeth of the timing signal disc are formed as required, enabling the sensor to detect signals normally, thereby ensuring precise fuel injection control by the timing signal electronic fuel injection system. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the dual-stage multi-wedge groove composite spun pulley with timing signal of this product;

[0027] Figure 2 This is a schematic diagram of the round cake material being prepared.

[0028] Figure 3 This is a schematic diagram of the raw material after drawing and shaping;

[0029] Figure 4 This is a schematic diagram of the raw materials after the edge trimming process.

[0030] Figure 5 This is a schematic diagram of the raw material after the machine edge is spun;

[0031] Figure 6 This is a schematic diagram of the raw material for punching mounting holes after spin forming;

[0032] Figure 7 This is a schematic diagram of leveling raw materials after punching the mounting holes;

[0033] Figure 8 This is a schematic diagram of the raw material for punching the timing hole after leveling;

[0034] Figure 9 This is a schematic diagram showing the positioning of the spinning raw material;

[0035] Figure 10 This is a schematic diagram of a spinning die;

[0036] Figure 11 This is a schematic diagram of the installation of the curling wheel for spinning forming dies;

[0037] Figure 12 yes Figure 11 A magnified view of a portion of the image;

[0038] Figure 13 This is a schematic diagram of the installation of the flat roller of the spinning die;

[0039] Figure 14 yes Figure 13A magnified view of a portion of the image;

[0040] Figure 15 This is a schematic diagram of the installation of the preforming wheel in a spinning die.

[0041] Figure 16 yes Figure 15 A magnified view of a portion of the image;

[0042] Figure 17 This is a schematic diagram of the installation of the forming wheel in a spinning die.

[0043] Figure 18 yes Figure 17 A magnified view of a portion of the image;

[0044] In the diagram: 1. Double-stage multi-ribbed composite spinning pulley with timing signal; 2. Circular disc; 3. Shaping material; 4. Edge-cutting material; 5. Spinning material; 6. Punching mounting hole material; 7. Leveling material; 8. Punching timing hole material; 101. Groove; 102. Arc; 103. Frustum-shaped cap; 104. Bevel; 105. Arc; 106. Chamfer; 201. Lower core mold; 202. Material limiting groove; 203. Lifting hole; 204. Connecting plate; 205. Lower fixing seat of spinning machine; 206. Ejector; 207. Upper core mold; 208. Spinning... 209. Press upper fixed seat; 210. Edge rolling wheel; 211. Flat spinning wheel; 212. Pre-forming wheel; 213. Forming wheel; 214. Lower ejection mechanism of spinning press; 215. Upper stop; 216. Inner hole stop; 217. Lower stop; 218. Upper stop of connecting plate; 219. Lower stop; 220. No. 1 spinning wheel seat; 221. No. 2 spinning wheel seat; 222. No. 3 spinning wheel seat; 223. No. 4 spinning wheel seat; 224. Center hole; 225. Bolt hole; 226. Pin hole; 227. Timing hole; 228. Timing signal tooth; 229. Notch. Detailed Implementation

[0045] Figure 1 The side wall of the double-stage multi-wedge groove composite spinning pulley 1 with timing signal has two stages of multi-wedge groove composite spinning pulley, and a ring of timing signal teeth 228 is provided on the cap at the end.

[0046] The processing technology of the present invention includes the following steps:

[0047] A. Blanking: Using a 250T punch press, cut 4.5mm thick SPHE hot-rolled steel plates into several round discs. The formula for calculating the disc diameter is: D=2. +2, where V is the volume of the double-stage multi-wedge groove composite spinning pulley with timing signal; π is pi; d is the thickness of SPHE hot-rolled steel plate, 4.5mm. The diameter of the circular disc 2 can be calculated as D=354mm.

[0048] B. Drawing and forming: The circular blank 2 is drawn and formed to obtain the shaped raw material 3, which is processed into a structure with a groove 101 and an arc 102 at the end; to facilitate the forming of subsequent processes; wherein the groove 101 has a depth of 7.9mm and is connected by 3 transition arcs, wherein the three arcs are R2.3, R9.3 and R2 respectively, and the arc 102 at the end is R13mm;

[0049] C. Shaping: The shaping raw material 3 is reshaped to obtain the edge-turning raw material 4, which is processed into a structure with a beveled end (i.e., a frustum-shaped brim) 103. The angle between the beveled surface 104 of the frustum-shaped brim 103 and the horizontal plane is 15°±0.25°. The beveled surface 104 and the straight surface of the part body are transitioned by an arc 105 with a radius of R2.

[0050] D. Edge turning: Edge turning raw material 4 is performed to turn the burrs and fringe of the outer circle of the part end to a smooth finish. The outer circle diameter of the part is turned to φ247±0.1mm to obtain spinning raw material 5. Both the upper and lower surfaces of the machined surface need to be chamfered 106 to remove burrs. The chamfer 106 is 1mm x 45°.

[0051] E. For example Figure 10-18Spin forming: The spin forming raw material 5 is spun using a 100T spinning machine to form the raw material 6 with punched mounting holes, which has two levels of multi-wedge grooves; during spinning, the spin forming raw material 5 is placed in the limiting groove 202 of the lower core mold 201 of the spinning die, which can ensure that the spin forming raw material 5 coincides with the center of the entire spinning die device. The lower core mold 201 has lifting holes 203 to facilitate the loading of the die into the spinning machine. The lifting holes 203 have a diameter of φ12mm and a depth of 12mm and are symmetrically distributed. The mold 201 and the connecting plate 204 are fixed together with four M12 bolts, and then mounted on the lower fixed base 205 of the spinning machine. The connecting plate 204 is fixed together with the lower fixed base 205 of the spinning machine with six M12 bolts. The ejector 206 is inserted into the inner hole of the lower core mold 201, completing the installation of the lower half. The upper core mold 207 is fixed together with the upper fixed base 208 of the spinning machine with four M12 bolts, completing the installation of the upper half. After the equipment is closed, the spinning machine presses the spinning raw material 5 tightly onto the upper core mold. Between 207 and the ejector 206, four sets of rotating wheels feed and extrude the spinning raw material 5 in sequence, ultimately machining a double-stage multi-wedge groove on the outer wall of the spinning raw material 5. The four sets of rotating wheels are the edge-rolling wheel 209, the flat-rolling wheel 210, the pre-forming wheel 211, and the forming wheel 212. After the four sets of rotating wheels finish feeding in sequence, the spinning machine opens the mold upwards for return, and the lower ejector mechanism 213 of the spinning machine pushes the ejector 206 upwards. The ejector 206 pushes the part out of the lower core mold 201, making it easy for the operator to remove the part. At this point, the spinning forming process is completed, and the raw material 6 for punching mounting holes is obtained; four sets of spinning wheels are mounted on spinning wheel seat 1# 220, spinning wheel seat 221, spinning wheel seat 3# 222 and spinning wheel seat 4# 223. Driven by the hydraulic servo system of the spinning machine side cylinder, the four spinning wheels can achieve radial feed and return along with the four spinning wheel seats. The four spinning wheels complete the feed and return in sequence, completing the entire spinning forming process; during the upward return of the spinning machine, the lower ejector mechanism 213 and ejector 206 of the spinning machine participate in the unloading of the material;

[0052] F. Punching mounting holes: Place the raw material 6 for punching mounting holes, which has been processed in the previous process, into the die for punching mounting holes to process the mounting holes of the part, which are used to tighten the bolts during engine assembly. The raw material 7 is then processed into a flat material; it includes a center hole 224 for center positioning on the engine, six bolt holes 225 for tightening the bolts on the engine, and a pin hole 226 for angle positioning when installed on the engine.

[0053] G. Leveling: Place the leveling raw material 7, which has been processed in the previous process, into the leveling mold, and process the 15° slope at the end of the part into a horizontal state to make the punching hole raw material 8.

[0054] H. Timing Hole Punching: Using a 400T four-column hydraulic press, the timing signal teeth at the end of the part are machined to obtain the final product, a double-stage multi-wedge groove composite spun pulley 1 with timing signal. Specifically: The raw material 8 for punching the timing hole, which has been processed in the previous process, is placed into the timing hole punching mold to machine the timing hole 227 of the part, which is used to read the timing signal after the engine is assembled. The timing signal teeth 228 are 60 evenly distributed. Two teeth are removed at a specified angle to form a notch 229, which is used for the engine sensor to identify the timing signal. Finally, a double-stage multi-wedge groove composite spun pulley 1 with timing signal is machined with 58 signal teeth on the outer circumference of the end.

[0055] The ejector 206 and the lower core mold 201 are clearance-fitted, with the clearance between 0.03mm and 0.05mm, which ensures that the two are concentric. The material limiting groove 202 of the lower core mold 201 is clearance-fitted with the outer diameter of the spinning raw material 5, with the clearance between 0.2mm and 0.3mm.

[0056] The upper stop 214 of the upper core mold 207 is clearance-fitted with the inner hole stop 215 of the upper fixed seat 208 of the spinning machine, with a clearance of 0.02mm-0.05mm, ensuring that the upper core mold 207 coincides with the center of the spinning machine; the lower stop 216 of the lower core mold 201 is clearance-fitted with the upper stop 217 of the connecting plate, with a clearance of 0.02mm-0.05mm, ensuring that the lower core mold 201 coincides with the center of the connecting plate 204; the lower stop 218 of the connecting plate 204 is clearance-fitted with the lower stop 219 of the lower fixed seat 205 of the spinning machine, with a clearance of 0.02mm-0.05mm, ensuring that the lower core mold 201, the connecting plate 204, and the ejector 206 coincide with the center of the spinning machine.

[0057] The entire surface of the edge-rolling wheel 209 is composed of several arcs and straight lines, each segment being sequentially labeled as: a1, a2, a3, a4, a5, a6, a7, a8, a9, a10, a11, a12, a13. Here, a1 is a straight line segment with an angle of 20°±10′ to the horizontal plane; a2 is an arc with a radius of R2±0.05; a3 is an arc with a radius of R2±0.05; and a4 is an arc with a radius of R2±0.05. Arcs: a5 is a vertical line segment, a6 is an arc with radius R2±0.05, a7 is an arc with radius R10±0.05, a8 is an arc with radius R2±0.05, a9 is a vertical line segment, a10 is an arc with radius R5±0.05, a11 is an arc with radius R26±0.05, a12 is an arc with radius R2±0.05, and a13 is a straight line segment with an angle of 20°±10′ to the horizontal plane.

[0058] The entire surface of the flat-rotating wheel 210 is composed of several arcs and straight lines, each segment being sequentially labeled as: b1, b2, b3, b4, b5, b6, b7, b8, b9, b10, b11, b12, b13, b14. Among them, b1 is a straight line segment with an angle of 20°±10′ to the horizontal plane, b2 to b5 are arcs with a radius of R1±0.05, b6 is an arc with a radius of R1.5±0.05, b7 is an arc with a radius of R1±0.05, b8 is an arc with a radius of R9±0.05, b9 is an arc with a radius of R1±0.05, b10 is an arc with a radius of R1.5±0.05, b11 to b13 are arcs with a radius of R1±0.05, and b14 is a straight line segment with an angle of 20°±10′ to the horizontal plane.

[0059] The problem of insufficient material stockpiling causing difficulty in forming the two-stage multi-wedge groove arc R0.45 is solved by using edge rolling wheel compensation and flat spinning wheel compensation.

[0060] The preformed wheel 211 has a profile composed of several arcs and straight lines, with a groove in the middle with a depth of 3.5±0.03. The lower half of the groove has 8 tooth tips with a radius of 0.6±0.03, 7 tooth roots with a radius of 0.6±0.03, 6 tooth pitches with a radius of 3.56±0.03, and 8 tooth angles with a radius of 60°±0.05°. The upper half of the groove has 6 tooth tips with a radius of 0.6±0.03, 5 tooth roots with a radius of 0.6±0.03, 4 tooth pitches with a radius of 3.56±0.03, and 6 tooth angles with a radius of 60°±0.05°.

[0061] The entire surface of the forming wheel 212 is composed of several arcs and straight lines, with a groove in the middle with a depth of 4.14±0.03. The lower half of the groove has 8 tooth tips with a radius of 0.45±0.03, 7 tooth roots with a radius of 0.42±0.03, 6 tooth pitches with a radius of 3.56±0.03, and 8 tooth angles with a radius of 40°±0.05°. The upper half of the groove has 6 tooth tips with a radius of 0.45±0.03, 5 tooth roots with a radius of 0.42±0.03, 4 tooth pitches with a radius of 3.56±0.03, and 6 tooth angles with a radius of 40°±0.05°. When the four rotating wheels complete the feeding in sequence, the outer circular tooth shape of the raw material 6 for punching the mounting hole can be obtained. This tooth shape is the position for installing the belt during engine assembly.

[0062] After spinning, the tooth wall thickness is compared with the raw material thickness. The deformation is 30%-35%. If the deformation is too large, the base material will form peeling and wrinkles near the lower core mold 201 during spinning. If the deformation is too small, the tooth will not be full during forming or the tooth tip will be missing material, which will cause the risk of cutting the belt after the engine is installed.

[0063] The spinning machine requires a main cylinder pressure of 13-16 MPa and a side cylinder pressure of 13-16 MPa. The main cylinder's rapid traverse speed is 35 mm / s-40 mm / s, and the working feed speed is 4 mm / s-8 mm / s. The edge-rolling wheel 209 has a rapid traverse speed of 35 mm / s-40 mm / s and a working feed speed of 2.0 mm / s-2.5 mm / s. The flat spinning wheel 210 has a rapid traverse speed of 35 mm / s-40 mm / s and a working feed speed of 0.6 mm / s-1.2 mm / s. The pre-forming wheel 211 has a rapid traverse speed of 35 mm / s-40 mm / s and a working feed speed of 0.6 mm / s-1.2 mm / s. The forming wheel 212 has a rapid traverse speed of 35 mm / s-40 mm / s and a working feed speed of 0.5 mm / s-1.0 mm / s.

[0064] Figure 2 In the process, a 250T punch press is used to make several circular discs with a diameter of D=354mm from the rolled SPHE steel plate.

[0065] Figure 3 In the process, a 400T four-column hydraulic press is used to stretch and shape the round cake into shape, forming the raw material 3;

[0066] Figure 4 In the process, a 400T four-column hydraulic press is used to reshape the raw material 3 to obtain the edge material 4;

[0067] Figure 5 In the middle, a CNC lathe with a hydraulic chuck turns the edge of the raw material 4, removing the burrs and rough edges at the end of the part, and obtaining a spun raw material 5 with an outer diameter of φ247±0.1mm at the end.

[0068] Figure 6 In the process, a 100T four-station spinning machine is used to spin the raw material 5 to obtain the raw material 6 with double-stage multi-wedge strip punched mounting holes; when installing the spinning die, first use bolts to fix the lower core die 201 to the connecting plate 204, then use bolts to fix the connecting plate 204 to the lower connecting seat 205 of the spinning machine, and then put the ejector 206 into the lower core die 201. At this time, the lower half of the spinning die is installed.

[0069] Then, use bolts to fix the upper core mold 207 onto the connecting seat 208 on the spinning machine, and install the four sets of spinning wheels: edge rolling wheel 209, flat spinning wheel 210, pre-forming wheel 211 and forming wheel 212 into the four sets of spinning wheel seats: #1 spinning wheel seat 220, #2 spinning wheel seat 221, #3 spinning wheel seat 222 and #4 spinning wheel seat 223 respectively. At this time, the upper part of the spinning mold and the four sets of spinning wheels are installed.

[0070] Start the 100T four-station spinning machine. Sequentially reset the four spinning wheel seats: #1 spinning wheel seat 220, #2 spinning wheel seat 221, #3 spinning wheel seat 222, and #4 spinning wheel seat 223 back to the coordinate origin. Reset the upper part upwards back to the coordinate origin. Place the spinning raw material 5 into the limiting groove 202 of the lower core mold 201 of the spinning die. Use the limiting groove 202 of the lower core mold 201 for center positioning. Start the processing button. The main cylinder of the spinning machine will hydraulically servo. The system drives the entire upper part downwards until the upper and lower parts are joined together. Then, the spinning machine begins to rotate. Simultaneously, the hydraulic servo system of the spinning machine's side cylinder sequentially drives four sets of spinning wheel seats: #1 spinning wheel seat 220, #2 spinning wheel seat 221, #3 spinning wheel seat 222, and #4 spinning wheel seat 223, connected to four sets of spinning wheels: edge-rolling wheel 209, flat spinning wheel 210, pre-forming wheel 211, and forming wheel 212, rapidly feeding the spinning raw material 5 until it is about to contact the... When the part is being processed, the side cylinder hydraulic servo system switches to slow feed, squeezing the straight-walled material of the spinning raw material 5 inward until the entire spinning process is completed. After the forming wheel 212 feeds to the center, the raw material for punching the mounting hole is obtained. At this time, the four sets of spinning wheels: the edge-rolling wheel 209, the flat spinning wheel 210, the pre-forming wheel 211, and the forming wheel 212, and the four sets of spinning wheel seats: #1 spinning wheel seat 220, #2 spinning wheel seat 221, #3 spinning wheel seat 222, and #4 spinning wheel seat 223, driven by the side cylinder hydraulic servo system, quickly retreat to the coordinate origin. At the same time, the upper part of the entire spinning die also quickly retreats to the coordinate origin under the drive of the main cylinder hydraulic servo system. Then, the lower ejector mechanism 213 of the spinning machine begins to feed upward, pushing the ejector 206 to feed upward together. The spun part is ejected by the ejector 206, and the obtained raw material for punching the mounting hole is taken out. The entire processing process is completed.

[0071] Figure 7 In the process, a 160T punch press is used to process the mounting holes of the parts, resulting in a leveled raw material 7;

[0072] Figure 8 In the process, a 200T four-column hydraulic press is used to process the beveled surface of the part end to a horizontal state, thus obtaining raw material 8 for punching the straight hole.

[0073] Figure 9In the spinning process, after the spinning equipment is closed and before spinning, the upper surface M1 of the spinning raw material 5 on the mounting plate is positioned by the upper core mold. The circumferential direction of the machined surface M3 of the frustum-shaped cap 103 of the spinning raw material 5 is positioned by the outer wall of the limiting groove 202 on the lower core mold 201. The outer wall of the limiting groove 202 is clearance-fitted with the machined surface of the frustum-shaped cap 103 before spinning. The inner wall of the limiting groove 202 is connected to the positioning inclined surface. The inner side of the inner surface M2 of the frustum-shaped cap 103 of the spinning raw material 5 is fitted and positioned with the positioning inclined surface. The outer side of the inner surface of the frustum-shaped cap 103 of the spinning raw material 5 is suspended above the limiting groove 202. Without the limiting groove, the material on the pulley would flow outward and flip upward during spinning. The reasonable design of the limiting groove ensures the thickness of the timing signal teeth 228 and the proper forming of the signal teeth of the timing signal disc, enabling the sensor to detect the signal normally, thus ensuring the precise control of the fuel injection quantity by the timing signal electronic injection system.

Claims

1. A manufacturing process for a two-stage multi-wedge groove composite spinning pulley with timing signal, characterized in that: Includes the following steps: Hot-rolled steel plates of thickness d are cut into round cakes (2). The circular cake (2) is drawn into a shaping raw material (3). The shaping raw material (3) includes an mounting plate and a cylindrical wall extending along the axial direction. The cylindrical wall has a port arc (102) at the end, and the radius of the port arc (102) is R1. The end of the shaping material (3) is shaped to obtain the edge material (4). The edge material (4) includes a frustum-shaped brim (103) located at the end. The outer surface of the longitudinal section of the frustum-shaped brim (103) is an inclined plane (104). The angle between the inclined plane (104) and the horizontal plane is a. The frustum-shaped brim (103) is connected to the cylinder wall by a rounded corner. The radius of the arc between the outer wall of the cylinder wall and the inclined plane (104) is R2, where R1 > R2. The outer edge and rough edge of the frustum-shaped brim (103) are machined to a smooth finish. Both the top and bottom of the machined surface M2 need to be chamfered (106) to remove burrs, and the spinning raw material (5) is obtained. The spinning raw material (5) is positioned and pressed by the spinning die of the spinning equipment. After the spinning equipment is closed and before spinning, the upper surface M1 of the spinning raw material (5) on the mounting plate is positioned by the upper core die. The circumferential direction of the machined surface M3 of the frustum-shaped cap (103) of the spinning raw material (5) is positioned by the outer wall of the limiting groove (202) on the lower core die (201). The outer wall of the limiting groove (202) is clearance-fitted with the machined surface of the frustum-shaped cap (103) before spinning. The inner wall of the limiting groove (202) is connected to the positioning slope. The inner side of the inner surface M2 of the frustum-shaped cap (103) of the spinning raw material (5) is attached to the positioning slope for positioning. The outer side of the inner surface of the frustum-shaped cap (103) of the spinning raw material (5) is suspended above the limiting groove (202). ; Ensure that the center of the spinning raw material (5) coincides with the center of the spinning die, perform spinning processing, and finally process a double-stage multi-wedge groove on the outer wall of the spinning raw material (5) to obtain the punched mounting hole raw material (6); After processing the mounting hole on the mounting plate of the punched mounting hole raw material (6), flatten the frustum-shaped brim to form a flat brim, and punch the straight hole at the edge of the flat brim; The diameter of the outer wall of the limiting groove (202) is 0.2-0.3mm larger than the diameter of the turning surface of the frustum-shaped brim (103) before spinning, the bottom of the limiting groove (202) is at least 2mm deeper than the lower surface of the frustum-shaped brim (103), the width of the limiting groove (202) is not greater than half the length of the positioning inclined surface, and the outer wall of the limiting groove (202) is H higher than the inner wall of the limiting groove (202), where H = the thickness d of the hot-rolled steel plate.

2. The manufacturing process for a two-stage multi-wedge groove composite spinning pulley with timing signal according to claim 1, characterized in that: The spinning die includes an upper core die (207) and a lower core die (201). An ejector (206) is placed in the inner hole of the lower core die (201). The lower core die (201) is a stepped cylinder, including a small cylinder for forming the inner wall of the spinning raw material (5) and a large cylinder connected to the lower part of the small cylinder. A connecting surface is provided at the connection between the small cylinder and the large cylinder. The connecting surface includes a forming surface located at the upper part for forming the end of the spun product and a positioning inclined surface connected to the lower end of the forming surface for positioning the inner surface of the frustum-shaped cap (103) before spinning. A material limiting groove (202) is provided on the upper end surface of the large cylinder of the lower core die (201).

3. The manufacturing process for a two-stage multi-wedge groove composite spinning pulley with timing signal according to claim 1, characterized in that: Four sets of rotating wheels feed the extrusion and spinning raw material (5) in sequence. The four sets of rotating wheels are the edge rolling wheel (209), the flat spinning wheel (210), the pre-forming wheel (211), and the forming wheel (212). The entire longitudinal section of the rolled edge wheel (209) is composed of several small segments connected in sequence. The small segments include circular arcs and straight lines. Each small segment is labeled from bottom to top as: a1, a2, a3, a4, a5, a6, a7, a8, a9, a10, a11, a12, a13. Among them, a1 is a straight line segment with an angle of 20°±10′ with the horizontal plane, a2 is a circular arc with R2±0.05, and a3 is a circular arc with R2±0.

05. a4 is an arc with a radius of 2 ± 0.05, a5 is a vertical line segment, a6 is an arc with a radius of 2 ± 0.05, a7 is an arc with a radius of 10 ± 0.05, a8 is an arc with a radius of 2 ± 0.05, a9 is a vertical line segment, a10 is an arc with a radius of 5 ± 0.05, a11 is an arc with a radius of 26 ± 0.05, a12 is an arc with a radius of 2 ± 0.05, and a13 is a straight line segment with an angle of 20° ± 10′ to the horizontal plane. The entire longitudinal section of the flat rotating wheel (210) is composed of several small segments connected in sequence. The small segments include circular arcs and straight segments. Each small segment is marked from bottom to top as: b1, b2, b3, b4, b5, b6, b7, b8, b9, b10, b11, b12, b13, b14. Among them, b1 is a straight segment with an angle of 20°±10′ with the horizontal plane, b2 to b5 are circular arcs with R1±0.05, b6 is a circular arc with R1.5±0.05, b7 is a circular arc with R1±0.05, b8 is a circular arc with R9±0.05, b9 is a circular arc with R1±0.05, b10 is a circular arc with R1.5±0.05, b11 to b13 are circular arcs with R1±0.05, and b14 is a straight segment with an angle of 20°±10′ with the horizontal plane. Spinning includes the following steps: First, the edge-rolling wheel (209) is rotated and moved horizontally to extrude the spun raw material (5) outward along the upper arc a11 of the edge-rolling wheel (209), the spun raw material (5) outward along the middle arc a7 of the edge-rolling wheel (209), and the spun raw material (5) forms the lower positioning teeth for positioning belts along the lower arcs a1-a4 of the edge-rolling wheel (209), and the top arcs a12 and a13 form the upper positioning teeth for positioning belts; Then, the flat spinning wheel (210) is rotated and moved horizontally to compress the spun raw material (5) outward along the upper arc a11 of the flat spinning wheel (210), and the spun raw material (5) continues to bulge outward along the middle arc b8 of the flat spinning wheel (210), and the spun raw material (5) continues to form positioning teeth for positioning belts along the lower arc b1-b4 of the flat spinning wheel (210), and the top arc b12 to b14 continues to form upper positioning teeth for positioning belts.

4. The manufacturing process for a two-stage multi-wedge groove composite spinning pulley with timing signal according to claim 1, characterized in that: Place the raw material (6) for punching mounting holes into the die for punching mounting holes, process the mounting holes on the mounting plate, and obtain the flattened raw material (7). Place the leveling raw material (7) into the leveling mold, and process the frustum-shaped cap (103) at the end of the part into a horizontal state to obtain the punching hole raw material (8). The timing hole raw material (8) is placed into the timing hole die to process the timing hole (227) of the part, which is used to read the timing signal after the engine is assembled. The timing signal teeth (228) are evenly distributed. Two teeth are removed at a specified angle to form a notch (229), which is used for the engine sensor to identify the timing signal. Finally, it is processed into a double-stage multi-wedge groove composite spinning pulley (1) with timing signal and N signal teeth on the outer circle of the port.

5. The manufacturing process for a two-stage multi-wedge groove composite spinning pulley with timing signal according to claim 3, characterized in that: The mounting holes include a center hole (224) for center positioning on the engine, six bolt holes (225) for bolting on the engine, and a pin hole (226) for angular positioning when mounted on the engine.

6. The manufacturing process for a two-stage multi-wedge groove composite spinning pulley with timing signal according to claim 1, characterized in that: The mounting plate is connected to the cylinder wall via a groove (101); the groove (101) includes a circular arc 1 at the position, a circular arc 2 connected to the inner end of the circular arc 1, and a circular arc 3 connected to the outer end of the circular arc 1, wherein the radius of the circular arc 1 is greater than the radius of the circular arc 2 and the radius of the circular arc 3.

7. The manufacturing process for a two-stage multi-wedge groove composite spinning pulley with timing signal according to claim 1, characterized in that: The main cylinder pressure required for the spinning machine is 13-16MPa, the side cylinder pressure is 13-16MPa, the main cylinder rapid advance speed is 35mm / s-40mm / s, the working speed is 4mm / s-8mm / s, the edge rolling wheel (209) rapid advance speed is 35mm / s-40mm / s, the working speed is 2.0mm / s-2.5mm / s, the flat spinning wheel (210) rapid advance speed is 35mm / s-40mm / s, the working speed is 0.6mm / s-1.2mm / s, the preforming wheel (211) rapid advance speed is 35mm / s-40mm / s, the working speed is 0.6mm / s-1.2mm / s, the forming wheel (212) rapid advance speed is 35mm / s-40mm / s, and the working speed is 0.5mm / s-1.0mm / s.

8. The manufacturing process for a two-stage multi-wedge groove composite spinning pulley with timing signal according to claim 1, characterized in that: After spinning, the deformation of the toothed wall thickness is 30%-35% compared with the thickness of the hot-rolled steel plate.

9. The manufacturing process for a two-stage multi-wedge groove composite spinning pulley with timing signal according to claim 1, characterized in that: The thickness of hot-rolled steel plates is 4.5-5.0 mm.

10. A double-stage multi-ribbed groove composite spinning pulley with timing signal produced by a manufacturing process for a double-stage multi-ribbed groove composite spinning pulley with timing signal (1).

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