CVT Belt Element Manufacturing via Combined Blanking and Plastic Deformation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing CVT belt elements require a separate taper portion forming step, increasing production costs and not optimizing yield effectively.
Innovation Solution
A method that omits the taper portion forming step by preparing a metal strip-shaped stock, performing a first blanking step along specific contour lines, followed by a plastic working step to form recessed and raised portions, and a second blanking step to cut out the element, ensuring high dimensional accuracy and smooth metal flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate taper portion forming step is added to manufacture CVT belt elements, then the manufacturing precision of the taper portion is improved, but the device complexity and production cost increase
Solution Approach 1:
The patent combines the taper portion forming operation with the main element forming operation into a single plastic working step. The forming die is designed with inclined surfaces that simultaneously create both the element shape and the taper portion, eliminating the need for a separate taper forming step while maintaining manufacturing precision
Solution Approach 2:
The blanking step is performed before the plastic working step to create a blank with specific contour lines that facilitate subsequent taper formation. By preparing the blank in advance with appropriate geometry, the taper portion can be formed efficiently during the plastic working step without requiring additional operations
2Productivity
If the stock width is increased to acquire even columns of elements, then the productivity is improved, but the loss of substance increases due to excess metal
Solution Approach 1:
The patent applies different geometric characteristics to different regions of the stock. Contour lines are added selectively at specific locations (lateral sides and bottom side of body portion) rather than uniformly across the entire stock, allowing metal flow optimization in critical areas while minimizing excess material in non-critical areas
Solution Approach 2:
The patent modifies the contour parameters by adding specific excess metal amounts at defined locations to enable proper metal flow during plastic working. The contour lines are positioned and dimensioned to provide just enough excess material for forming operations while minimizing overall waste, optimizing the balance between productivity and material utilization
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the production of CVT belt elements with high dimensional accuracy without the need for a separate taper portion forming step, reducing production costs and improving yield while maintaining smooth metal flow.
Implementation Method 1
a plastic working step of compressing the stock in a thickness direction to form predetermined recessed and raised portions and to form the taper portion while causing the metals to flow to the edge
Data Source
AI summary
Disclosed is a method for manufacturing an element for a CVT belt, comprising a body portion (22L, 22R) having right and left sides and a tapered portion with a downwardly reducing width, a neck portion extending upward from the body portion, and a head portion extending upward from the neck portion. The manufacturing method comprises a first punching step in which a metal strip blank (31) which has a uniform thickness and a width which makes it possible obtain elements arrayed on an even number of lines in an arrangement in which the head portions are opposed to each other or an arrangement in which the body portions are opposed to each other, is punched along an outline ((33L, 33R) of an excess material (21b) added to profiles of the left and right sides (21L, 21R) of the body portions, and along an outline (58L, 58R) of an excess material (32b) added to a profile of a lower side (32L, 32R) of the body portion; a plastic deformation step in which the blank is compressed in the thickness direction to form a predetermined projection and depression, and form the tapered portion while displacing the material in the outline directions; and a second punching step in which the element is obtained as a product by punching the blank.