Link Plate Shaving Method for Roller Chain Mold Life
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Solution Overview
Problem
Conventional link plate manufacturing methods for roller chains in internal combustion engines face issues such as shortened mold life, warping, and increased costs due to the use of expensive shaving molds and the generation of burrs and rough surfaces, which affect the strength and accuracy of the link plates.
Innovation Solution
A manufacturing method involving different working molds for rough punching and shaving, where the shaving range is defined to ensure tangency with the outermost sides of pin holes, reducing warping and extending mold life while using less expensive molds, thereby improving the surface finish and structural integrity of the link plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If expensive shaving molds are used to improve surface finish and remove burrs, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The invention segments the link plate into different regions (shaved region and non-shaved region) based on functional requirements. Only the peripheral portions requiring smooth surfaces for contact with tensioner lever or guide lever are shaved, while other regions retain the rougher punched surface. This selective segmentation reduces the area requiring expensive shaving operations.
Solution Approach 2:
The invention applies different surface qualities to different regions of the link plate. High-quality shaved surfaces are applied only where contact with other components occurs (peripheral portions), while non-contact regions maintain lower-quality rough surfaces. This local differentiation optimizes manufacturing cost by applying expensive processing only where necessary.
2Manufacturing precision
If the shaving mold contour is made larger than the link plate contour, then surface accuracy is improved, but the mold life is shortened due to contact with cutting margins
Solution Approach 1:
The shaving mold contour is designed to match the link plate contour exactly, rather than being larger. This local adaptation ensures the mold only contacts the intended peripheral portions requiring shaving, avoiding contact with cutting margins. The mold contour is locally optimized to follow the plate outline, preventing chipping and extending mold life.
3Ease of manufacture
If only peripheral portions are shaved to reduce cost, then manufacturing cost is reduced, but warping occurs at the boundary between shaved and non-shaved regions
Solution Approach 1:
The invention performs preliminary positioning by defining the shaving working range based on the outermost positions of pin holes. The shaving operation is pre-planned to extend to specific boundaries that account for potential warping. This preliminary action ensures that the boundary between shaved and non-shaved regions is positioned to minimize warping effects on the overall link plate stability.
4Manufacturing precision
If the working range for shaving is extended beyond the outermost positions of pin holes, then surface accuracy is improved, but the mold complexity increases
Solution Approach 1:
The shaving mold is designed with a contour that exactly matches the link plate contour, making it a universal solution that handles the entire peripheral portion requiring shaving. The mold serves multiple functions: it shaves the peripheral surfaces, defines the working range boundary, and prevents contact with cutting margins. This multi-functionality simplifies the overall system compared to having separate molds for different regions.
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
The method enhances the longevity of both the shaving molds and the link plates, reduces manufacturing costs, and prevents warping and breakage, leading to improved strength and reduced noise in the roller chain, ensuring uniform engagement and extended service life.
Implementation Method 1
by punching a band-shaped steel plate with a working mold (generally called a "punch") during rough punching referred to as primary processing as shown in FIG. 8(a) the peripheral portion of the band-shaped steel plate to be punched is punched to shave small amount of peripheral portions of the punched plate as shown in FIG. 8(b) so that any sag 10, rupture rough surface 20 and burr 30 generated during the rough punching with the punch are removed to improve the surface roughness and surface accuracy of the roughly punched peripheral portions
Data Source
AI summary
A method of manufacturing a link plate for a roller chain, and the resulting link plate in which (1) the link plate has a shape comprising a pair of right and left pin holes, a pair of right and left half arcs, which are spaced outwardly from the pin holes respectively, and a pair of upper and lower straight line portions connecting both ends of the pair of right and left half arcs. There are shaved lengths along the pair of upper and lower straight line portions extending into the half arcs, the shaved length extending between the outermost positions of both ends of said pin holes.