Splined Annular Component Forming Without Burr-Causing Machining
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Solution Overview
Problem
Current methods for manufacturing annular clutch components, such as Grob spline forming, require additional machining processes that result in burrs and poor surface finishes, increasing manufacturing costs and cycle times.
Innovation Solution
A multi-station transfer press process is used to form a splined annular component with a continuous inner diameter and smooth, mirror-like outer diameters, eliminating the need for machining and reducing cycle time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If Grob spline forming process is used to manufacture annular clutch components, then the component can be formed from sheet-metal blanks, but additional machining processes are required that result in burrs and poor surface finishes
Solution Approach 1:
The patent combines the spline forming operation with the initial cup-forming operation into a single draw forming process. The splines are formed directly on the hub segment during the drawing operation itself, eliminating the need for separate Grob spline forming and machining operations. This integration resolves the contradiction by achieving both manufacturing simplicity and high surface finish quality simultaneously.
Solution Approach 2:
The patent extracts the spline forming function from the traditional multi-step process (cup forming, then Grob splining, then machining) and incorporates it directly into the draw forming operation. By taking out the intermediate processing steps that cause burrs and poor surface finishes, the invention achieves high-quality surface finish while maintaining ease of manufacture.
2Manufacturing precision
If additional machining processes are used after Grob splining to form mounting segments and ensure flatness, then the required precision is achieved, but manufacturing costs and cycle times increase
Solution Approach 1:
The patent performs preliminary forming of the mounting segment and flat plate segment during the initial draw forming operation, before any subsequent processing. The cup-shaped blank is drawn with the final mounting segment geometry and flatness already established, eliminating the need for post-splining machining operations. This preliminary action resolves the contradiction by achieving required precision while reducing cycle time.
3Manufacturing precision
If the cutter tool cuts along the entire length of the plate segment to guarantee flatness, then the flatness requirement is met, but the interrupted cut causes material to be pushed down into the spline form as burrs
Solution Approach 1:
The patent converts the potential harm of cutting operations by eliminating them entirely. Instead of using a cutter tool that creates interrupted cuts and burrs, the invention forms the plate segment flatness and mounting segment geometry directly during the draw forming operation. The harmful burr-forming cutting action is replaced with a beneficial forming action that achieves the same flatness requirement without generating burrs.
Solution Approach 2:
The patent extracts the harmful cutting operation from the manufacturing process. By removing the cutter tool and machining operations entirely, the invention eliminates the source of burr formation while maintaining plate segment flatness through the draw forming process itself.
4Ease of manufacture
If broaching process is used to form external splines, then the splines can be formed by material removal, but the surface finish on the minor diameter and flanks is poor
Solution Approach 1:
The patent replaces the mechanical broaching system (which removes material and creates poor surface finish) with a draw forming system that forms splines through plastic deformation during the drawing operation. This substitution of the forming mechanism resolves the contradiction by achieving spline formation capability while producing superior surface finish on the spline flanks and minor diameter.
5Manufacturing precision
If one-shot forming process is used to form external splines, then the surface finish is improved relative to broaching, but the cycle time remains high and manufacturing cost is high
Solution Approach 1:
The patent merges the spline forming operation with the cup-forming operation into a single draw forming process. Instead of using a separate one-shot forming operation after cup formation, the splines are formed directly during the drawing operation itself. This consolidation resolves the contradiction by achieving high surface finish quality while reducing cycle time and manufacturing cost through process integration.
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 process achieves a high-quality surface finish, reduces manufacturing costs, and eliminates the need for deburring, resulting in a more efficient and cost-effective production method for torque-transmitting components.
Implementation Method 1
pressing the blank between the first die and the first punch to form a first cup-shaped preform of the unfinished component
Data Source
AI summary
A method of manufacturing a torque-transmitting component includes providing a flat blank to a transfer press having a plurality of stations and performing a plurality of pressing operations, in which the flat blank is formed into a cup shape, rough splines are formed on the cup shape, and the rough splines are further pressed to define smooth splines. The component includes a continuous smooth inner diameter defined by a punch of the transfer press and a plurality of smooth splines defined by a die of the transfer press. The minor diameter of the splines is not machined to form the splines.