Profile Roller Positioning for Toothed Cup Components
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Solution Overview
Problem
Existing methods for producing internally and externally toothed cup-shaped sheet material components, such as clutch plate carriers, face challenges with dimensional deviations and surface quality due to varying sheet materials and require significant time and effort for tool adjustment and maintenance.
Innovation Solution
A method and device that allow for the variable positioning of profile rollers during the production process, using a pick-up mandrel with a tooth-like profile and a set of profile rollers that can move radially to ensure accurate tooth formation, reducing the need for subsequent grinding and addressing anisotropic material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed positioning system for profile rollers is used, then the tool structure is simple and robust, but dimensional deviations occur due to varying sheet materials and extensive tool adjustments are required
Solution Approach 1:
The profile rollers are made movable along the generating line of the cup-shaped component through a mechanism involving guide wedges and adjusting elements. This dynamic positioning allows the rollers to adapt to dimensional deviations caused by varying sheet materials while maintaining manufacturing precision, resolving the contradiction between fixed structure simplicity and dimensional accuracy requirements
2Manufacturing precision
If profile rollers are made movable to adapt to material variations, then dimensional accuracy improves, but the device complexity and adjustment mechanism increase
Solution Approach 1:
The adjusting elements are designed to automatically compensate for dimensional deviations without requiring manual intervention. The profile rollers self-adjust along the generating line through the guide wedge mechanism, eliminating the need for extensive tool adjustments during maintenance or material changes, thus improving ease of operation while maintaining precision
3Force
If a massive receiving body structure is used for profile rollers, then force transfer during rolling is secure, but the device weight and inertia increase
Solution Approach 1:
The receiving body structure is segmented into modular components including guide wedges, adjusting elements, and individual profile roller holders. This segmentation maintains the necessary force transfer capability through each modular unit while reducing overall device weight and inertia compared to a single massive structure, allowing easier adjustment and maintenance
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 ensures precise dimensional accuracy and surface quality without the need for extensive tool adjustments, reducing production time and costs, and prevents the formation of undesirable 'tulip shapes' in high-speed transmission parts.
Implementation Method 1
the external profile is then rolled onto the cup-shaped sheet material component by pressing the cup-shaped sheet material component together with the pick-up mandrel through a set of profile rollers rolling in parallel to the center axis on the sheet material component while exerting a radial pressure, thereby pressing the material into the tooth grooves of the pick-up mandrel
Data Source
AI summary
A method and a device for producing an internally or externally toothed cup-shaped (body) sheet material component with alternating teeth and grooves that run in parallel to the center axis of the cup, especially of a clutch plate carrier. The method and device allow the use of profile rollers, the rollers controlling the true running, dimensional accuracy and the surface of the cup-shaped sheet material component having an internally and externally profiled wall in the shape of teeth, in such a manner that they guarantee a specifically variable position during production. An untoothed cup-shaped sheet material component is slid onto a pick-up mandrel which has an external toothing corresponding to the internal toothing of the sheet material component to be produced and the external profile is then rolled onto the cup-shaped sheet material component by pressing the cup-shaped sheet material component together with the pick-up mandrel by means of a set of profile rollers while exerting a radial pressure.