Trapezoidal Tooth Support Rings Multi-Stage Tooling
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Solution Overview
Problem
Existing manufacturing processes for roof tooth carrier rings in vehicle transmission synchronization systems face challenges in achieving high dimensional accuracy, freedom from burrs, and material strength due to limited tool guidance and multiple process steps, leading to low quality and high post-processing requirements.
Innovation Solution
A multi-stage cutting and forming tool with position search stamps and coordinated movement of upper and lower tools allows for precise positioning and embossing of roof shapes, profiling tooth formation, and waste removal in a single tool stage, ensuring accurate and durable ring production without additional processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple process steps and tool training are used for producing roof tooth carrier rings, then manufacturing flexibility is improved, but positioning accuracy and manufacturing precision deteriorate due to limited tool guidance
Solution Approach 1:
The manufacturing process is divided into multiple independent process steps (cutting positioning openings, middle layer pre-positioning, inserting, embossing outer edge, precise positioning, pre-embossing roof shape, intermediate embossing, final embossing, overall cutout, waste inner cutout, ring positioning, edge embossing, circumferential chamfer embossing, deposits embossing). Each step is performed by dedicated tool components that work sequentially, allowing high flexibility while maintaining precision through specialized function at each stage.
Solution Approach 2:
Positioning openings are cut in advance before the main forming operations. Middle layer pre-positioning and precise positioning steps prepare the sheet metal part with accurate reference features before the final embossing and cutting operations, ensuring that subsequent steps can achieve high precision without compromising manufacturing flexibility.
2Device complexity
If embossing punch is designed solely with tool guidance for upper and lower tools, then device complexity is reduced, but positioning accuracy and manufacturing precision deteriorate
Solution Approach 1:
The tooling system is segmented into multiple specialized components: cutting stamps for positioning openings, insertion stamps, embossing stamps for outer edge and roof shape, precise positioning stamps, cutting dies for overall contour and waste removal, ring positioning stamps, edge embossing stamps, circumferential chamfer stamps, and deposits embossing stamps. Each component has a specific function that contributes to overall precision without requiring complex integrated guidance systems.
Solution Approach 2:
Positioning openings and middle layer pre-positioning features act as intermediary reference elements that facilitate accurate positioning between different tool stages. These intermediary features enable precise alignment without requiring complex direct guidance between all tool components.
3Ease of manufacture
If process steps and tool training are independent of sheet thickness and material strength, then ease of manufacture is improved, but manufacturing precision deteriorates due to inability to accommodate varying material properties
Solution Approach 1:
The tooling system is designed with dynamic capabilities to adapt to different sheet thicknesses and material strengths. Each process step can be adjusted in terms of force application, positioning pressure, and forming parameters to match the specific material properties being processed, maintaining both ease of manufacture and high precision across varying material conditions.
Solution Approach 2:
The manufacturing process incorporates parameter adjustments for different materials and thicknesses, including but not limited to embossing pressure, cutting force, positioning tolerance, and forming speed. These parameter changes enable the same tooling system to achieve high precision across a range of material properties while maintaining ease of manufacture.
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 solution enables the production of roof tooth carrier rings with enhanced dimensional accuracy, material strength, and reduced burrs, meeting high quality standards while minimizing post-processing needs and tool complexity.
Implementation Method 1
A multi-stage cutting and forming tool with position search stamps and coordinated movement of upper and lower tools allows for precise positioning and embossing
Implementation Method 2
simultaneous embossing of an outer edge on the bottom side of each sheet metal part... pre-embossing of the roof shape, intermediate embossing of the roof shape... final embossing of the roof shape
Data Source
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AI summary
The application of roof tooth carrier rings, manufactured from prefabricated blanks (51) or from sheet metal strips (50) unwound from a coil, to clutch bodies in synchronization systems of vehicle transmissions requires high dimensional accuracy and freedom from burrs, as well as consistently good shaping and material strength in the profile-defining tooth shape and in the roof tooth formation. The process essentially consists of four process steps for center-position and anti-rotation positioning (1 to 4), which, together with the subsequent process steps of embossing (11 to 15) and cutting (10, 16, 17), are carried out with each stroke of the upper tool (40) of a multi-stage cutting and forming tool and a sheet metal part transfer in the process direction (8).The design of the tool is characterized by the position search dies (30) arranged at each tool stage, as well as the roof-shaped embossing dies (32) and further embossing and cutting dies (31 to 38).