Roll flanging process for flanging a workpiece with a roll flanging device

Abstract

The invention relates to a roll flanging method for flanging a workpiece 16 with a roll flanging device 10 for a machine tool, comprising the steps of: providing S1 of at least two individual parts to be joined, namely the workpiece 16, in a holding device 12; flanging S2 of the workpiece with a flanging roller 22 of a roll flanging device 10, wherein the held workpiece 16 is rotated about the main axis 18 and / or moved along the traverse axis perpendicular to the main axis 18, and wherein the flanging roller 22 is applied to a flanging lip 52 at a flanging angle 44 with a predetermined forming pressure in a feed direction 40, wherein a feed position of the flanging roller 22 is continuously determined by a control device by means of a measuring device 30, and the flanging step is terminated when the feed position reaches a predetermined threshold value; determining S3 whether a predetermined flanging end angle has been reached. and if not,Change S4 of the flanging angle 44 by a predetermined angle increment and repeat the flanging process S2 until the predetermined flanging end angle is reached.

Description

[0001] The invention relates to a roll flanging method for flanging a workpiece with a roll flanging device for a machine tool with a main axis.

[0002] Flanging is a joining technique in sheet metal processing and describes the joining of components through forming. The term flanging can refer, for example, to bending the edge of sheet metal using a flanging machine or by hand to stiffen the bent edge or to join components together at the edge. For instance, air duct connections or pipe connections in ventilation and refrigeration systems are gas-tightly joined by flanging.

[0003] For example, German patent application DE 10 2015 119 589 A1 describes a device and a method for robot-assisted roll folding. The device comprises a frame, a first roller, and a second roller, which, during operation, bear against two opposite sides of a workpiece. It also includes at least one first actuator, which is mechanically coupled to the frame and at least one of the two rollers and is controlled in such a way that process forces acting in opposite directions, approximately on the same line of action, are applied to the opposite sides of the workpiece via the two rollers. The two rollers are displaceable relative to the frame, so that mispositioning of the roll folding device relative to the workpiece can be compensated for by displacing the rollers relative to the frame.

[0004] Furthermore, publication GB 2 033 026 A describes the manufacture of a brush seal by winding one or more wire filaments onto a flat, annular or straight wax mandrel that has a metal bead along one edge. A retaining element with a channel or hairpin profile is placed over the bead, and the retaining element is crimped to clamp the filaments while the wax is simultaneously melted out. The filaments are then separated by grinding to form bristles that are anchored in the retaining element by the metal bead. However, the publication does not describe the technique used to crimp or deform the metal retaining element to hold the filaments.

[0005] It is therefore an object of the invention to provide a flanging process for a machine tool with which a variety of flanged components can be produced and which makes it possible to flange a workpiece quickly and efficiently.

[0006] The problem is solved by the roll flanging method according to claim 1. Advantageous further developments are described in the dependent claims.

[0007] According to a first aspect, a roll flanging process for flanging a workpiece with a roll flanging device for a machine tool with a main axis is provided, comprising the following steps: providing at least two individual parts to be joined, as the workpiece, in a holding device of the machine tool; flanging the held workpiece with a flanging roll of a roll flanging device, wherein the held workpiece is rotated about the main axis and the flanging roll is applied to a flanging lip of the workpiece at a flanging angle and is subjected to a predetermined forming pressure in a feed direction of the roll flanging device, wherein a feed position of the flanging roll in the feed direction is continuously determined by a control device by means of a measuring device of the roll flanging device and the flanging step is completed.When the feed position reaches or exceeds a predetermined threshold, determine whether a predetermined flanging angle has been reached, and if the flanging angle has not yet been reached, change the flanging angle by a predetermined angle increment and repeat the flanging process until the predetermined flanging angle is reached.

[0008] In other words, it is a roll flanging process for flanging the workpiece using a machine tool, such as a lathe, a turning machine, a CNC-controlled lathe, or a machining center equipped with a workpiece holder or clamping device, an interchangeable tool holder, and a control device (hereinafter referred to as "machine tool"). This machine tool has a main axis around which the workpiece can be rotated for machining with a tool that can be held in the tool holder. Alternatively, the machine tool may have a main axis in which a linear traverse axis of the workpiece is perpendicular to the main axis.

[0009] Furthermore, the workpiece has a flanged lip that projects from the workpiece in an initial direction. The flanged lip extends either circularly (or arc-shaped) along a circumferential direction about a central axis, or longitudinally along a traverse axis of the workpiece. If the machine tool has a main axis, this main axis can be parallel to the central axis, allowing the workpiece to be rotated about the main axis. Alternatively, the main axis can be parallel to the traverse direction. In this case, the traverse direction can correspond to the traverse axis of the workpiece.

[0010] When the flanged lip is fully crimped, the angle at which an end section of the flanged lip is crimped corresponds to the specified crimping end angle. In other words, before crimping, the flanged lip protrudes from the workpiece in the starting direction (the end section of the flanged lip points in the direction of the starting direction), and after crimping, the flanged lip is crimped (bent over) and the end section of the flanged lip is crimped by the crimping end angle.

[0011] It can therefore also be said that the present disclosure provides a roll flanging method for flanging a workpiece with a roll flanging device for a machine tool, wherein the method comprises the following steps: - Providing at least two individual parts to be joined as the workpiece in a holding device of the machine tool, - Flanging the held workpiece with a flanging roller of a rolling flanging device, wherein the held workpiece is rotated by the machine tool about a central axis of the workpiece and / or moved along a traversing axis of the workpiece, the flanging roller is applied to a flanging lip of the workpiece at a flanging angle and is subjected to a predetermined forming pressure in a feed direction of the rolling flanging device, wherein a feed position of the flanging roller in the feed direction is continuously determined by a control device by means of a measuring device of the rolling flanging device and the flanging step is terminated when the feed position reaches or exceeds a predetermined threshold value, wherein the flanging lip projects from the workpiece in the direction of an exit direction and extends in the direction of the traversing axis, - Determine whether a predetermined flanging angle has been reached, which corresponds to a predetermined direction of an end section of the flanging lip after flanging, and - if the flanging angle has not yet been reached, change the flanging angle by a predetermined angle increment and repeat the flanging step until the predetermined flanging angle is reached.

[0012] In a first step, at least two parts to be joined are positioned as the workpiece in the holding device (clamping jaws) of the machine tool. The holding device serves to hold the workpiece and rotate it, along with the holding device, around the main axis of the machine tool. The holding device can be, for example, a clamping device or another type of holding device that can positively lock the workpiece. For example, the parts to be joined can comprise a base body and a cover ring, or they can comprise, for example, the base body, a brush body, and the cover ring. However, any workpiece that includes a (fully or partially) circular flanged lip can be flanged using the roll flanging process.After the rolling flanging device is mounted in the tool holder of the machine tool, the second step involves flanging the workpiece with the flanging roller of the rolling flanging device. The workpiece is rotated (by means of the holding device) about its main axis and / or moved along a traversing axis perpendicular to the main axis, and the flanging roller is applied to the flanging lip (standing seam) of the workpiece or a bendable or flangable strip of the workpiece at the predetermined flanging angle. The flanging lip is preferably designed as a projection, with the workpiece being held such that the flanging lip projects from the workpiece opposite to the direction of the main axis and extends along the traversing axis.The flanging lip is subjected to the specified forming pressure (flanging pressure) in the feed direction of the rolling flanging device, whereby the feed position of the flanging roller in the feed direction is continuously determined by the control unit using the measuring device of the rolling flanging device. In other words, the extent to which the flanging roller has deformed the flanging lip and how far the flanging roller has moved in the direction of the flanging lip (in the feed direction) is continuously measured. Since the workpiece is simultaneously rotated in the machine tool and / or moved along the travel axis perpendicular to the main axis, the feed position can be measured or determined as a feed position dependent on a rotation angle or travel position of the machine tool.In the next step, it is determined whether the feed position reaches or exceeds the specified threshold value; in other words, whether the flanging lip has reached a specific bending position. This is achieved, for example, if the specified threshold value is reached or exceeded for every rotation angle or travel position of the machine tool, or if the specified threshold value is reached or exceeded for essentially every rotation angle or travel position of the machine tool. Applying the specified forming pressure to the rolling flanging device can be achieved, for example, by moving the rolling flanging device a predetermined distance in the feed direction through the machine tool via the holding device after detecting that the flanging roller is in contact with the flanging lip (detectable by a deflection on the measuring device).This feed path can be calculated, for example, from the specified forming pressure and a spring constant of the actuator. If the actuator has a linear motor and / or a pneumatic element, the forming pressure can also be generated directly by the linear motor and / or the pneumatic element. The actuator thus enables the flanging roller holder to be moved in the feed direction and pressure to be exerted on the flanging roller holder in the feed direction.

[0013] If it is determined that the threshold value is reached or exceeded, the rolling flanging device is applied to the workpiece at a different flanging angle. In other words, the flanging angle is changed (increased or decreased) by a predetermined amount (angle increment), and the flanging process is repeated with the modified angle until a predetermined final flanging angle is reached. For example, the flanging process can be performed in four steps. The flanging angle can be, for example, an angle between the main axis (or a direction parallel to the main axis) and the feed direction of the rolling flanging device. The rolling flanging device can, for example, be moved in a plane that contains the main axis and whose surface normal is perpendicular to the main axis.

[0014] The roll flanging process according to the invention enables a consistently high level of quality in the flanged components and a high quantity of flanged components to be produced. Furthermore, automation and operation of the machine tool without user intervention can, for example, reduce the risk of operator injury. The linear traverse movement in the feed direction at a predetermined flanging angle allows for simple implementation in the machine tool. Thus, automation results in high process stability, high efficiency, excellent quality, and cost and time savings compared to manual production.Because the roll flanging device is a tool guided in the tool holder and stored in a tool magazine of the machine tool, it can be automatically changed via a detachable machine interface. Furthermore, freely adjustable forming pressure (flanging pressure, working pressure) and precise setting of the forming pressure can be achieved by the actuator or by the machine guide of the roll flanging device's tool holder.

[0015] Furthermore, the automatic determination of the flanging roller's feed position enables precise detection of a pressure point on the component (tolerance detection). In other words, the continuous determination of the flanging roller's feed position makes it easy to detect when no further bending of the flanging lip occurs or is possible, because the flanging lip cannot be bent further below the given flanging angle, for example, because it has reached a position where it rests against the cover ring.

[0016] Furthermore, different flanging radii and shapes can be achieved without creating unwanted pressure points on the flared parts. Component tolerances can thus be easily compensated for, and the multiple angle settings allow for simple adjustment of the individual flanging radius on the component.

[0017] The invention includes further advantageous embodiments that provide additional benefits.

[0018] According to a further advantageous embodiment, it is provided that the determination of the feed position by the control device involves transmitting the feed position from the measuring device. The measuring device can be equipped with a wireless communication module that transmits the feed position in the feed direction of the rolling flanging device to the machine tool's control unit via a wireless communication technology such as WLAN or Bluetooth®, enabling the control unit to determine the feed position. The advantage of this design is that the wireless communication module (radio module) allows the rolling flanging device to be used in a machine tool with automatic tool changes in a particularly simple manner, without requiring a wired power supply and / or data connection between the measuring device and the control unit.Thus, the feed position can be continuously determined using the wireless communication module of the measuring device, and at the same time a high degree of automation can be achieved through the roll flanging device.

[0019] According to a further advantageous embodiment, the roll flanging process includes the step of axially centering the workpiece in the machine tool after the flanging end angle has been reached, followed by machining or reworking of an outer contour of the workpiece. In other words, after the flanging end angle has been reached, the workpiece is axially centered in the machine tool, allowing it to be released from the clamping device and its outer contour to be machined with a tool of the machine tool. This makes it possible to re-turn, over-turn, or re-machine the outer contour of the workpiece using a cutting tool.This can, for example, ensure that the runout error of the flanged brush seal or the flanged lip with respect to the outer contour of the workpiece approaches zero, or that the outer contour has a precisely defined distance to the brush seal.

[0020] According to a further advantageous embodiment, the flanging process is repeated multiple times, in particular three times, and the flanging end angle is between 0° and 180°, particularly 90°. In other words, the flanging is performed in several steps (for example, two, three, four, or five steps), and the flanging end angle is designed such that the flanged lip is flanged by an angle in the range of 0° to 180°, in particular 45°, 90°, or 135°. By flanging in several steps, especially steps of equal size, a very good overall flanging result can be achieved. Furthermore, the risk of errors is significantly reduced compared to roll flanging processes, in which flanging is performed in only one or two steps. Moreover, flanging in only one step is not advantageous, as it would introduce a force perpendicular to a principal direction of extension of the flanged lip.As an example, a flanging process can be carried out in four steps, where the steps are performed such that in the first step a flanging angle of 22.5° is set, in the second step a flanging angle of 45°, in the third step a flanging angle of 67.5°, and in the fourth step the final flanging angle of 90° is set. As described above, the risk of errors increases with a smaller number of flanging steps; on the other hand, flanging in more than four or five steps is not recommended, as the time required for the roll flanging process increases significantly in this case.

[0021] According to a further advantageous embodiment, the workpiece comprises a base body, a brush body, and a cover ring as the individual parts to be joined. In other words, the base body can include the crimped lip, which, after crimping, securely holds the cover ring by positive locking. The brush body is securely held by the connection between the base body and the cover ring. Preferably, the brush body can point towards the center of the base body, and the crimped lip can be bent axially inwards. However, it is equally possible for the brush body to point axially outwards (away from the main axis), and for the crimped lip to be bent axially outwards. This arrangement of base body, brush body, and cover ring allows for a particularly advantageous manufacturing process for a brush ring seal.

[0022] The invention further comprises a roll flanging device for use with a machine tool having a main axis, according to the roll flanging method as described above. The roll flanging device includes a housing with a connection section, in particular a receiving flange, for connection to the machine tool, a flanging roller holder which is movably attached to the housing in the feed direction via an actuator, and a measuring device which is configured to determine a feed position of the flanging roller holder and thus a feed position of the flanging roller in the feed direction. In other words, the roll flanging device includes the connection section, in particular the receiving flange, with which the roll flanging device can be held in the machine tool. The roll flanging device also has the housing which includes the flanging roller holder and the measuring device.The flanging roller holder is movably mounted to or within the housing, allowing it to move only in the feed direction. This movement can be achieved via an actuator, such as a spring element (e.g., with disc springs), a linear motor, a pneumatic element, and / or a magnetic element. The actuator enables the flanging roller holder to move in the feed direction and exert pressure on it during this direction. The flanging roller can be held in the holder by a ball bearing, such as a heavy-duty ball bearing. The measuring device can be integrated into the housing or attached to it.The measuring device can, for example, be a stroke indicator or a linear measuring device that can determine the feed position of the driver, and thus of the flanging roller holder and the flanging roller, in the feed direction. As previously described, the measuring device can include a wireless communication module that can transmit the measured feed position in the feed direction to the control unit of the machine tool so that the control unit can determine the feed position. The invention can thus be implemented in a simple manner using the roll flanging device.

[0023] According to a further advantageous embodiment, the flanging angle is an angle between the main axis of the machine tool and the feed direction of the rolling flanging device. Advantageously, the flanging angle is set by the machine tool by rotating the machine tool's mounting relative to the main axis by the flanging angle and / or moving it along the travel axis perpendicular to the main axis, positioning the rolling flanging device against the workpiece at the given flanging angle, and applying the flanging pressure.

[0024] According to a further advantageous embodiment, the flanging roller holder comprises a flanging roller which is connected to the holder by means of a bearing, in particular a heavy-duty ball bearing. In other words, the flanging roller is rotatably mounted in the holder and can rotate about an axis that preferably lies in the same plane as the main axis of the machine tool. The bearing is preferably a heavy-duty ball bearing in order to be able to absorb the forces that occur particularly advantageously. Furthermore, the flanging roller can, for example, be driven by a motor which can be integrated into the holder to reduce forces acting on the flanging roller, the holder, and the flanging device.

[0025] According to a further advantageous embodiment, a rotation axis of the flanging roller is located perpendicular to the feed direction of the rolling flanging device. In other words, a rotation axis of the flanging roller can be aligned perpendicular to the feed direction of the rolling flanging device, so that no laterally acting forces (with respect to the feed direction) can be exerted on the feed direction of the rolling flanging device. Reducing or eliminating laterally acting forces can facilitate, in a particularly simple way, the application of a force to the flanging roller in the feed direction, to the workpiece in the feed direction, and / or to the flanging lip of the workpiece.

[0026] According to a further advantageous embodiment, the measuring device includes a wireless communication module by means of which the measuring device can transmit the measured feed position in the feed direction to a control unit of the machine tool. As described above, the wireless communication module enables communication with the control unit of the machine tool without the need for a wired connection. For this purpose, the wireless communication module preferably includes its own power supply. This can, for example, be a battery, a rechargeable battery, a solar cell, or a device for generating energy from, for example, a force such as pressure or vibration, from electrical voltages, from temperature differences, from light, or radio waves in the form of electromagnetic radiation.The continuously determined feed position in the feed direction can thus be transmitted to the machine tool's control unit in a particularly simple manner. The wireless measuring probe (the measuring device with the wireless communication module) therefore enables the roll flanging device to be used particularly advantageously and reliably in a CNC machine tool with automatic tool changing.

[0027] Further features and advantages of one of the described embodiments of the invention may arise from further developments of another embodiment of the invention. The features of the embodiments of the invention can thus exist in any combination with one another, unless they have been explicitly described as mutually exclusive.

[0028] Additional features and advantages of the invention are described below with reference to the figures in the form of advantageous embodiments. The features or combinations of features of the embodiments described below can be present in any combination with one another and / or with the features of the embodiments. That is, the features of the embodiments can complement and / or replace the features of the embodiments, and vice versa. Thus, embodiments that are not explicitly shown or explained in the figures, but which can be derived and generated from separate combinations of features in the embodiments and / or embodiments, are also to be considered as encompassed and disclosed by the invention.Thus, embodiments that do not exhibit all the features of an originally formulated claim, or that go beyond or deviate from the combinations of features set out in the references of the claims, are also to be considered disclosed.

[0029] Examples of implementation show: Fig. 1 a schematic representation of a roll flanging device according to an exemplary embodiment when used in a machine tool; Fig. 2 a schematic representation of the roll flanging device according to the exemplary embodiment; Fig. 3 a schematic sectional view of the roll flanging device according to the exemplary embodiment; Fig. 4a a schematic sectional view of a workpiece in one step of the roll flanging process according to an exemplary embodiment; Fig. 4b a schematic sectional view of the workpiece in one step of the roll flanging process according to the exemplary embodiment; Fig. 4c a schematic sectional view of the workpiece in one step of the roll flanging process according to the exemplary embodiment; Fig. 4d a schematic sectional view of the workpiece in one step of the roll flanging process according to the exemplary embodiment; Fig. 4e a schematic sectional view of the workpiece in one step of the roll flanging process according to the exemplary embodiment; and Fig. 5 a schematic flowchart of the roll flanging process according to an exemplary embodiment.

[0030] Fig. Figure 1 shows a schematic representation of a roll flanging device 10 according to an exemplary embodiment when used in a machine tool. The machine tool includes a holding device 12 in which the workpiece 16 is held. The workpiece 16 can be rotated about the main axis 18 of the machine tool along a direction of rotation 14 and / or moved along the traverse axis perpendicular to the main axis. The roll flanging device 10 can be positioned against the workpiece 16 and pressure can be applied to the workpiece 16 to crimp a flanging lip 52.

[0031] Fig. Figure 2 shows a schematic representation of the roll flanging device 10 according to the exemplary embodiment. The roll flanging device 10 has a housing 36 which includes a connection section that is in Fig. 2 is shown as the (schematically depicted) mounting flange 38. The rolling flanging device 10 can be inserted into or connected to a (not shown) tool holder of the machine tool by means of the connecting section or the mounting flange 38, or the rolling flanging device 10 can be received in the tool holder of the machine tool. The rolling flanging device 10 comprises a flanging roller holder 26, which can hold a flanging roller 22 via a roller axle 24. The flanging roller 22 can include a (not shown) ball bearing, such as a heavy-duty ball bearing. The flanging roller holder 26 is movably mounted within the housing 36 such that it can move in a feed direction 40 while being rotationally secured.A driver 28 moves along with the flanging roller holder 26 in the feed direction 40, enabling the measuring device 30 (also called a probe or length measuring device) to determine the feed position of the flanging roller 22 in the feed direction 40. The measuring device 30 can be attached to the housing 36 by means of a clamping device 32. The measuring device 30 has a wireless communication module 34 to transmit the measured feed position, or a positional displacement of the driver 28 due to a change in the position of the flanging roller holder 26, and thus the feed position of the flanging roller 22, to the control device of the machine tool.

[0032] Fig. Figure 3 shows a schematic sectional view of the roll flanging device 10 according to the exemplary embodiment. As before, the roll flanging device 10 comprises the housing 36 in which the flanging roller holder 26 is linearly displaceable. An actuator 42, shown here as a coil spring, can move the flanging roller holder 26 in the feed direction 40 or exert pressure in the feed direction, and can thus move the flanging roller 22 in the feed direction 40, which is rotatably mounted on the flanging roller holder 26. The rotatable mounting is achieved by means of a (not shown) ball bearing, roller bearing, or the like at the position of the roller axis 24.The driver 28 is carried along during movement of the flanging roller holder 26 in the feed direction (in both directions: forward and backward), thus enabling the measuring device 30 to measure the feed position of the flanging roller 22 relative to the housing 36, and the control unit to continuously determine the measured feed position of the flanging roller 22 relative to the housing 36. The measuring device 30 is attached to the housing 36 in the clamping fixture 32. The measuring device 30 includes the wireless communication module 34, which transmits the determined position to the control unit of the machine tool.

[0033] Fig. Figure 4a shows a schematic sectional view of a workpiece 16 in a first step of the roll flanging process according to an exemplary embodiment. Fig. Figure 4a shows a base body 50 into which a brush body 54 can be inserted. This is indicated by a small arrow showing the installation direction of the brush body 54 in the base body 50. The base body 50 has a crimped lip 52 that can be crimped. The crimped lip 52 projects from the workpiece 16 along the initial direction 58. A cover ring 56 can be placed on the brush body 54 to compensate for tolerances of the brush body 54 and to hold it securely.

[0034] For better understanding, the following is included in the Fig. Figures 4a to 4e each show only one side of a sectional view through the annular base body 50, the brush body 54, and the cover ring 56. A central axis of each annular body 50, 54, and 56 can, for example, be seen on the left side of the Fig. Located between 4a and 4e.

[0035] Fig. Figure 4b shows a schematic sectional view of the workpiece in one step of the roll flanging process according to the exemplary embodiment. Here, the roll flanging device 10, and thus the flanging roller 22, is positioned against the flanging lip 52 of the base body 50 of the workpiece 16 at a first flanging angle α1 (flanging angle 44). A forming pressure (flanging pressure) is exerted on the flanging roller 22, acting in the feed direction 40. The flanging angle 44 is an angle between a direction 62 of the machine tool parallel to the main axis 18 and the feed direction 40.

[0036] Fig. Figure 4c shows a schematic sectional view of the workpiece in one step of the roll flanging process according to the exemplary embodiment. Fig. Figure 4c shows the roll flanging process in an advanced stage, wherein the flanging lip 52 was flanged around the flanging angle α1 in the previous step, and the flanging lip 52 according to Fig. 4c projects in the direction 60 of the end section of the flanging lip 52. In this step, the flanging roller 22 is applied to the flanging lip 52 at a second flanging angle α2 (flanging angle 44) and subjected to a flanging pressure. According to the roll flanging process, a feed position in the feed direction 40 is measured by the measuring device 30 of the roll flanging device 10 and continuously determined by the control unit. As soon as the feed position reaches or exceeds a predetermined threshold value, it is determined that the flanging step has been completed and the next flanging angle 44 can be set. The flanging angle 44 can be increased by a predetermined angle increment before each subsequent flanging step. The next flanging step is then carried out with the increased or modified flanging angle 44.

[0037] Accordingly, it shows Fig. Figure 4d shows a schematic sectional view of the workpiece 16 in one step of the roll flanging process according to the exemplary embodiment. The flanging lip 52 was crimped by the flanging angle α2 in the previous step, and the end section of the flanging lip 52 projects according to Fig. 4d in direction 60, which forms an angle α2 with the initial direction 58. In this step, the flanging roller 22 is positioned against the flanging lip 52 at a third flanging angle α3 (flanging angle 44) and subjected to a flanging pressure in the feed direction 40. Thus, the flanging lip 52 can be further flanged in this step.

[0038] Fig. Figure 4e shows a schematic sectional view of the workpiece 16 after one step of the roll flanging process according to the exemplary embodiment. In this step, the flanging end angle α4 (flanging angle 44) is set, and the flanging roller 22 is positioned against the flanging lip 52 in the feed direction 40, and a final flanging step is performed. After the flanging step, the workpiece 16 is as shown in Figure 4e. Fig. Figure 4e shows the flange completely rolled and the roll flanging process can be completed. Preferably, the angle α4 (flanging angle 44) is 90° between a direction 62 parallel to the main axis 18 of the machine tool and the feed direction 40 of the roll flanging device 10. After completion of the final flanging step, the flange lip 52 is rolled by the flanging angle α4, and the end section of the flange lip 52 projects according to Fig. 4e in the direction 60, which encloses the angle α4 with the initial direction 58.

[0039] Fig.Figure 5 shows a schematic flowchart of a roll flanging process according to an exemplary embodiment. In a first step S1, at least two individual parts to be joined, namely the workpiece 16, are placed in the holding device 12 of the machine tool. The at least two individual parts to be joined can, for example, comprise the base body 50, the brush body 54, and the cover ring 56. In a step S2, the workpiece 16 is flanged with the flanging roller 22 of the roll flanging device 10, wherein the held workpiece 16 is rotated about the main axis 18 and / or moved along the traverse axis perpendicular to the main axis 18, and wherein the flanging roller 22 is applied to the flanging lip 52 of the workpiece 16 at the flanging angle 44.The flanging roller 22 is subjected to the specified forming pressure or flanging pressure in the feed direction 40 of the rolling flanging device 10. The feed position of the flanging roller 22 is measured by the measuring device 30 of the rolling flanging device 10 and continuously determined by the control unit. The measured feed position can be transmitted to the control unit via the wireless communication module 34. As soon as the feed position reaches or exceeds a specified threshold, the process proceeds to step S3. In step S3, it is determined whether the flanging end angle has been reached. If the flanging end angle has been reached, the process proceeds to an optional step S5. If the flanging end angle has not yet been reached, the flanging angle is changed or increased by a specified angle increment in step S4.(Alternatively, the flanging angle can be reduced in each step S4). After step S4, the process returns to step S2 to repeat the flanging step S2 with the modified flanging angle 44. In the optional step S5, after reaching the final flanging angle, the workpiece can additionally be held axially centered in the machine tool and a machining operation, such as turning or post-machining of an outer contour of the workpiece 16, can be performed. This step S5 offers the advantage that the runout error of the outer contour with respect to the flanged lip is reduced to a very low degree, or that the outer contour has a precisely defined distance to the brush seal.

[0040] A particularly preferred embodiment is described below.

[0041] Components to be flanged can be pre-assembled on a conventional machine and held in a defined position using a fixture. In several manual steps, a flange lip can be bent over and the workpiece joined simultaneously, using predefined angles. An operator can produce the component using a specially designed forming tool (the roll flanging device) and an analog dial gauge (measuring device). Further steps, such as post-processing of surfaces and various checks using measuring instruments, are also required.

[0042] Due to the manual nature of the processes involved in manual manufacturing, there is a risk that the quality and quantity of the formed components will not reach a consistent level. Another potential hazard is that the open, non-enclosed machine poses a risk of injury.

[0043] Many automation concepts are known, such as CNC machines and robots, but a roll flanging device is not yet known. Regarding tools and integration with a suitable machine, there are no commercially available solutions. Furthermore, tolerances in the assembly often result in different initial conditions and / or starting points.

[0044] For the automated application of the flanging forming process, a new tool (roll flanging device) has been equipped with a measuring system that offers a significant improvement over manual steps. The tool automatically compensates for tolerances on the component (workpiece) through a combination of linear traverse motion (in the feed direction), a ball screw (flanging roller), and a dial gauge (measuring device). This compensation ensures a precise positioning position for the component. The influence of component tolerances on the flanging process is largely eliminated. The tool can be used on different machines with simple interface modifications. Due to the automation, the advantages include increased process stability, greater efficiency, improved quality, and significant cost and time savings.

[0045] The roll flanging device offers the following advantages: • It is a guided tool, • that can be inserted into a tool magazine of the machine tool. • The tool can be automatically changed via a detachable machine interface (mounting device). • It can be used for different component sizes and / or component types. • It can be used for various component contours (radii, corners and edges). • The working pressure can be easily adjusted by means of an exact pressure force setting via an actuator (spring package) and a feed of the machine tool. • The operating pressure can be easily adjusted on the component. • Precise pressure point detection (tolerance detection) on the component is possible. • Different flanging radii and flanging shapes can be produced. • The crimped parts do not include any unwanted pressure points. • Component tolerances can be easily compensated for. • One or more angles of attack can result in an individual flanging radius on the component.

[0046] How it works: • The roll flanging device has a base part (housing) with an interface that can be accommodated in machine tools. • The base part includes a linear flanging roller holder to which the pressure roller (flanging roller) is mounted. • The compression spring (actuator) acted on the pressure roller in the feed direction. • The measuring probe (measuring device) can be calibrated; the travel distance to the spring assembly (actuator) is known. • The pressure roller (flaring roller) touches the component, the measuring probe measures a length measurement signal (calculation signal). • The linear feed path to be set is determined by the machine control (control unit) based on the length measurement signal. • The machine feed moves the base part (housing) and the actuator (spring assembly) in the feed direction and presses the actuator. • The measuring probe measures the remaining linear feed, the machine control calculates the remaining distance. • The flanging roller holder and the flanging roller (pressure roller) are pre-tensioned and pressurized by the calculated feed with the actuator (spring assembly; for example, disc springs). • The flanging contour can be generated using several angles of attack, which can be stored in the machine program.

[0047] The invention relates to a roll flanging method for flanging a workpiece 16 with a roll flanging device 10 for a machine tool, comprising the steps of: providing S1 of at least two individual parts to be joined, namely the workpiece 16, in a holding device 12; flanging S2 of the workpiece with a flanging roller 22 of a roll flanging device 10, wherein the held workpiece 16 is rotated about the main axis 18 and / or moved along the traverse axis perpendicular to the main axis 18, and wherein the flanging roller 22 is applied to a flanging lip 52 at a flanging angle 44 with a predetermined forming pressure in a feed direction 40, wherein a feed position of the flanging roller 22 is continuously determined by a control device by means of a measuring device 30, and the flanging step is terminated when the feed position reaches a predetermined threshold value; determining S3 whether a predetermined flanging end angle has been reached; and if notChange S4 of the flanging angle 44 by a predetermined angle increment and repeat the flanging process S2 until the predetermined flanging end angle is reached. Reference symbol list: 10 Roll-Flanging Device 12 Holding device 14 Direction of rotation or direction of travel 16 workpieces 18 Main axis 22 Flanging roller 24 roller axle 26 Flanging roller holder 28 drivers 30 Measuring device 32 Clamping 34 Wireless communication module 36 cases 38 Mounting flange 40 Feed direction 42 Actuator 44 Flanging angle 50 basic shapes 52 Bördellippe 54 brush bodies 56 Deck ring 58 Starting direction 60 End section direction 62 Direction parallel to the main axis

Claims

Roll flanging method for flanging a workpiece (16) with a roll flanging device (10) for a machine tool with a main axis (18), comprising the steps: - providing (S1) at least two individual parts to be joined as the workpiece (16) in a holding device (12) of the machine tool, - flanging (S2) the held workpiece (16) with a flanging roll (22) of a roll flanging device (10), wherein the held workpiece (16) is rotated by the machine tool about the main axis (18) and / or moved along a traversing axis perpendicular to the main axis (18), the flanging roll (22) is applied to a flanging lip (52) of the workpiece (16) at a flanging angle (44) and is subjected to a predetermined forming pressure in a feed direction (40) of the roll flanging device (10),wherein a feed position of the flanging roller (22) in the feed direction (40) is continuously determined by a control device using a measuring device (30) of the roller flanging device (10) and the flanging step (S2) is terminated when the feed position reaches or exceeds a predetermined threshold value, - Determine (S3) whether a predetermined flanging end angle has been reached, and - if the flanging end angle has not yet been reached, change (S4) the flanging angle (44) by a predetermined angle increment and repeat the flanging step (S2) until the predetermined flanging end angle is reached. Roll flanging method according to claim 1, wherein determining the feed position by the control device comprises transmitting the feed position from the measuring device (30) to the control device by means of a wireless communication module (34). Roll flanging method according to claim 1 or 2, wherein the method comprises the step: - after reaching the flanging end angle, axially centrally holding the workpiece (16) in the machine tool and machining over-turning or machining post-processing (S5) of an outer contour of the workpiece (16). Roll flanging method according to one of the preceding claims, wherein the flanging (S2) is repeated several times and the flanging end angle is between 0° and 180°. Roll flanging method according to one of the preceding claims, wherein the workpiece (16) comprises a base body (50), a brush body (54) and a cover ring (56) as the individual parts to be joined.

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