Disk Carrier Flow-Forming with Preformed Annular Shoulder
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Solution Overview
Problem
The production of disk carriers with cylindrical peripheral walls and radial annular grooves is complex due to the difficulty in precisely shaping the radial shoulder area during flow-forming, requiring post-processing machining which is inefficient and limited in extent.
Innovation Solution
A method where the disk carrier is formed in one piece by flow-ironing a starting workpiece with preformed annular shoulder, groove, and radial openings, maintaining the microstructure and efficiently producing a precisely manufactured annular shoulder area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If flow-forming is used to produce disk carriers with two circumferential sections of offset diameters, then productivity is improved by one-piece manufacturing, but manufacturing precision deteriorates because the annular groove and groove wall cannot be precisely shaped
Solution Approach 1:
The manufacturing process is segmented into two distinct phases: (1) pre-forming the annular groove and groove wall with radial openings in the starting workpiece using conventional machining to achieve high precision, and (2) subsequently flow-forming the peripheral wall sections to achieve high productivity. This segmentation allows each process to optimize for its specific function without compromising the other.
Solution Approach 2:
The annular groove and groove wall structure is prepared in advance (pre-formed) in the starting workpiece before the flow-forming process begins. This preliminary action ensures that the critical dimensions are established with high precision through machining before the material is deformed during flow-forming, preventing distortion of these critical features.
2Manufacturing precision
If post-processing machining is applied to form the annular groove and groove wall after flow-forming, then manufacturing precision is improved, but device complexity increases and productivity decreases
Solution Approach 1:
Instead of performing machining operations after flow-forming, the annular groove and groove wall are pre-formed in the starting workpiece before the flow-forming process. This reversal of the operation sequence eliminates the need for complex post-processing equipment and operations, reducing device complexity while maintaining manufacturing precision.
Solution Approach 2:
The complex post-processing machining operations are extracted from the production sequence and replaced by pre-forming operations on the starting workpiece. This extraction eliminates the need for additional machining equipment and operations that would increase device complexity, while the pre-formed structure remains intact through the flow-forming process.
3Productivity
If flow-forming is used to produce the disk carrier, then productivity is improved, but manufacturing precision deteriorates in the radial shoulder area
Solution Approach 1:
The radial shoulder area with the annular groove and groove wall is pre-formed in the starting workpiece before flow-forming begins. This preliminary formation ensures that the radial shoulder geometry is established with high precision through conventional machining, and this pre-formed structure is then preserved during the subsequent flow-forming process, maintaining precision while achieving high productivity.
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
Enables the production of disk carriers with precisely manufactured annular shoulder areas and efficient one-piece flow-forming, reducing manufacturing complexity and improving dimensional accuracy.
Implementation Method 1
the disk carrier is formed in one piece by flow ironing of the peripheral wall with the first peripheral section, the second peripheral section and the axial lamellae from a starting workpiece
Data Source
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AI summary
The application relates to a disc carrier having: a cylindrical peripheral wall which has a first peripheral portion having a first diameter and an axially adjoining second peripheral portion having a second diameter, the second diameter being larger than the first diameter, and the first peripheral portion and the second peripheral portion being connected to each other by a radial annular step; rib-like axial projections which are provided on the inner side of the first peripheral portion and/or the second peripheral portion; and an annular groove which is provided on the inner side of the annular step and between the second peripheral portion and a radially inner, axially projecting groove wall that has radial openings. According to the invention, the disc carrier is integrally formed by flow forming of the peripheral wall with the first peripheral portion, the second peripheral portion and the axial projections from a starting workpiece, the annular step with the annular groove and the groove wall with the radial openings being formed prior to the flow forming.