Method and device for producing an internally and externally toothed pot-shaped sheet metal part using a forming head

Abstract

A method for producing an internally and/or externally toothed pot-shaped sheet metal part having teeth extending toward the pot center axis, wherein an un-toothed pot-shaped sheet metal part is inserted into a die and then, by means of a relative movement between the sheet metal part and associated profile rollers, a profile is rolled onto the pot-shaped sheet metal part by the profile rollers applied to the sheet metal part and thus alternating internal and external gear teeth are applied to the sheet metal part, wherein the profile rollers form the sheet metal part oriented radially from the inside toward the outside, in that the profile rollers roll along the inner circumference of the sheet metal part.

Claims

1. A method using a forming device for producing a toothed pot-shaped sheet metal part having teeth extending toward a pot central axis, comprising: inserting a pot-shaped sheet metal part into a die, the pot-shaped sheet metal part having a medial plane, and wherein the pot center axis extends perpendicular to the medial plane, then, by relative movement between the pot-shaped sheet metal part and a first forming head comprising first forming bodies on an outer circumference thereof, performing a forming operation by rolling a profile onto the pot-shaped sheet metal part by the first forming bodies applied to the pot-shaped sheet metal part to apply alternating internal and external gear teeth to the pot-shaped sheet metal part, radially from an inside area toward an outside periphery of the sheet metal part, and wherein the first forming bodies roll along an inner circumference of the pot-shaped sheet metal part in a direction parallel to the pot central axis and perpendicular to the medial plane of the pot-shaped sheet metal part, and completely move through the pot-shaped sheet metal part so that the first forming bodies exit back out of the pot-shaped sheet metal part thereby forming the toothed pot-shaped sheet metal part.

2. The method according to claim 1, wherein a stripper, which is movable separately from the forming head, is arranged on an upper tool of the forming device, and the method further comprises ejecting the pot-shaped sheet metal part, by the stripper, after the forming operation, and holding the pot-shaped sheet metal part in place by a ring plate when the upper tool is moved upward.

3. The method according to claim 1, wherein the first forming bodies are adjustable and fixable in cassette-shaped receptacles by path displacement radially in relation to gear teeth in the die.

4. The method according to claim 1, wherein the first forming bodies are radially adjustable during the forming operation.

5. The method according to claim 1, wherein a second forming head having cassettes acts oriented from the outside toward the inside on the pot-shaped sheet metal part, the second forming head comprising second forming bodies are oriented radially inward on an outer circumference of the pot-shaped sheet metal part.

6. A method using a forming device for producing a toothed pot-shaped sheet metal part having teeth extending toward a pot central axis, comprising: inserting a pot-shaped sheet metal part into a die, then, by relative movement between the pot-shaped sheet metal part and a first forming head comprising first forming bodies on an outer circumference thereof, performing a forming operation by rolling a profile onto the pot-shaped sheet metal part by the first forming bodies applied to the pot-shaped sheet metal part to apply alternating internal and external gear teeth to the pot-shaped sheet metal part, radially from an inside area toward an outside periphery of the sheet metal part, and wherein the first forming bodies roll along an inner circumference of the pot-shaped sheet metal part in a direction of the pot central axis, and completely move through the pot-shaped sheet metal part so that the first forming bodies exit back out of the pot-shaped sheet metal part thereby forming the toothed pot-shaped sheet metal part, wherein a second forming head having cassettes acts oriented from the outside toward the inside on the pot-shaped sheet metal part, the second forming head comprising second forming bodies are oriented radially inward on an outer circumference of the pot-shaped sheet metal part, and wherein, introducing, a ring-shaped die between an outer circumference and an inner circumference of the pot-shaped sheet metal part to produce a double-walled pot-shaped sheet metal part, to roll gear teeth onto the outer circumference and gear teeth onto the inner circumference of the pot-shaped sheet metal part while using a combination of the first and second forming heads.

7. A device for producing a toothed pot-shaped sheet metal part having teeth extending toward a pot center axis, comprising: a die into which an un-toothed pot-shaped sheet metal part is inserted, and forming bodies configured to be applied to the un-toothed pot-shaped sheet metal part by a relative movement between the un-toothed sheet metal part and a forming head provided with the forming bodies on an outer circumference thereof, the forming bodies being arranged and oriented radially outside on the forming head to roll along an inner circumference of the un-toothed pot-shaped sheet metal part in a direction parallel to the pot center axis, and configure to create alternating internal and external gear teeth on the un-toothed pot-shaped sheet metal part, the forming bodies being configured to completely pass through the un-toothed pot-shaped sheet metal part so that the forming bodies exit from the un-toothed pot-shaped sheet metal part to form the toothed pot-shaped sheet metal part, and a pressure ring or another pressure element to form gear teeth on the un-toothed pot-shaped sheet metal part, the gear teeth being conical in a longitudinal direct and configured to exert a pressure oriented in an axial direction on cassettes containing the forming bodies during a downward stroke of the forming device, wherein the cassettes comprise conically beveled back plates configured to move radially inward on conically beveled guide surfaces of a stop bushing to provide a continuous and/or step-by-step adjustment of a radial forming depth of the cassettes.

8. A device for producing a toothed pot-shaped sheet metal part having teeth extending toward a pot center axis, comprising: a die into which an un-toothed pot-shaped sheet metal part is inserted, and forming bodies configured to be applied to the un-toothed pot-shaped sheet metal part by a relative movement between the un-toothed sheet metal part and a forming head provided with the forming bodies on an outer circumference thereof, the forming bodies being arranged and oriented radially outside on the forming head to roll along an inner circumference of the un-toothed pot-shaped sheet metal part in a direction parallel to the pot center axis, and configure to create alternating internal and external gear teeth on the un-toothed pot-shaped sheet metal part, the forming bodies being configured to completely pass through the un-toothed pot-shaped sheet metal part so that the forming bodies exit from the un-toothed pot-shaped sheet metal part to form the toothed pot-shaped sheet metal part, and a first collar of cassettes arranged on the forming head, and at least a second collar of cassettes arranged above the first collar on the forming head.

9. The device according to claim 7, wherein each cassette has a back plate, which is replaceable and which is configured to enable a radial adjustment of the cassette in a radial direction on the un-toothed pot-shaped sheet metal part depending on a thickness of the back plate.

10. The device according to claim 9, wherein each of the back plates of the cassettes are applied to cylindrical guide surfaces, which are aligned in parallel to a movement direction of the forming head, on the stop bushing.

11. The device according to claim 7, wherein the forming bodies are implemented as axle-free mounted profile rollers or as pressure parts or as balls or as pins, rollers, or other rotatable bodies and at least one forming body is mounted in each cassette.

12. The device according to claim 7, the forming bodies are mounted on axes in the cassette.

13. The device according to claim 7, wherein a first set of forming bodies are provided and oriented radially from an inside area to an outside area for forming an inner circumference of the toothed pot-shaped sheet metal part, the first set of forming bodies are configured to roll along the inner circumference of the un-toothed pot-shaped sheet metal part in a direction parallel to the pot center axis, and a second set of forming bodies being provided and oriented radially from the outside are toward the inside area for forming an outer circumference of the toothed pot-shaped sheet metal part.

14. The device according to claim 7, further comprising a deep-drawing tool, which leads the forming bodies.

15. The device according to claim 8, wherein each cassette has a back plate, which is replaceable and which is configured to enable a radial adjustment of the cassette in a radial direction on the un-toothed pot-shaped sheet metal part depending on a thickness of the back plate.

16. The device according to claim 15, wherein each of the back plates of the cassettes are applied to cylindrical guide surfaces, which are aligned in parallel to a movement direction of the forming head, on the stop bushing.

Description

(1) The invention will be explained in greater detail hereafter on the basis of drawings which illustrate multiple embodiments. In this case, further features essential to the invention and advantages of the invention result from the drawings and the description thereof.

(2) In the figures:

(3) FIG. 1: shows a section through a forming device in the open state

(4) FIG. 2: shows a section through the forming device according to FIG. 1 in the contact position

(5) FIG. 3: shows a section through the forming device according to FIGS. 1 and 2 in the closed position

(6) FIG. 4: shows an enlarged illustration of the roller head in section

(7) FIG. 5: shows a section through a cassette

(8) FIG. 6: shows an installation example for a cassette according to FIG. 5

(9) FIG. 7: shows a perspective illustration of the roller head with partially shown cassettes

(10) FIG. 8: shows a perspective illustration of a cassette with an installed profile roller

(11) FIG. 9: shows the cassette according to FIG. 8, wherein the closure plate was removed

(12) FIG. 10a: shows a perspective illustration of a double-toothed workpiece

(13) FIG. 10b: shows a section through the workpiece according to FIG. 10a

(14) FIG. 10c: shows a perspective bottom view of the workpiece according to FIG. 10a

(15) FIG. 11: shows a sectional illustration of the production of a single-walled and double-toothed workpiece

(16) FIG. 12: shows a sectional illustration of the production of a double-walled and double-toothed workpiece

(17) FIG. 13: shows a sectional illustration of an alternative forming device having a two-step forming tool

(18) The forming device according to FIGS. 1 to 3 substantially consists of an upper tool 1 and a lower tool 2 arranged underneath in relation thereto.

(19) A number of downwardly oriented guide columns 3 are provided on the upper tool 1, which plunge into the guide receptacles 4 when the upper tool 1 is lowered in the arrow direction 27 toward the lower tool 2.

(20) In this manner, the upper tool 1 is centered in relation to the lower tool 2.

(21) On the lower tool 2, a recess is arranged in a clamping plate 44, in which a counter holder piston 7 is held so it is movable via further holding plates. The drive of the counter holder piston is not shown in greater detail. It plunges through a ring space 24, which is arranged centrally in the interior of a ring receptacle 10.

(22) A die 5 having associated, inwardly oriented gear teeth 6 is arranged on the ring receptacle 10. The sheet metal part 9, which is not yet formed, is seated on the die 5, wherein internal centering is performed via the forming plate 8. A gap is present between the outer circumference of the forming plate 8 and the inner circumference of the die 5 provided with the gear teeth 6.

(23) In the exemplary embodiment shown, the sheet metal part 9 has an outwardly oriented flange 43, which is equipped with a larger circumference. An application of gear teeth by a forming head (roller head 23), as is described in the prior art, would therefore not be possible.

(24) For this reason, the invention provides that a forming head 23 is provided with forming bodies (profile rollers 22), which are oriented from the inside toward the outside.

(25) According to FIG. 1, the forming head 23 consists of a rotationally-symmetrical holder 11, which is fastened in the upper tool 1 and which is penetrated by a stripping tool. The stripping tool consists of a stripper 14, which is provided with a lower ring plate 13.

(26) Two sets of forming bodies in the implementation of profile rollers 22 are arranged in two working layers 36, 37 lying one above the other (see FIG. 4) in the holder 11, these forming bodies being received in a rotatable and axle-free manner in associated cassettes 17, 18.

(27) Two stop bushings 21 located one above the other are provided, which are connected together by a central fastening screw 19, so that this fastening screw 19 holds together the entire package having the stop bushings 21 and the cassettes 17, 18, which are arranged in two working layers and at a mutual distance to one another.

(28) The lower ring of cassettes 18 is held and guided by a lower indexing plate 20, while the upper ring of cassettes 17 is held and guided by an upper indexing plate 35.

(29) In the functional position shown in FIG. 1, the open location of the upper tool is shown in comparison to the lower tool 2.

(30) In FIG. 2, the same parts are provided with the same reference signs as in FIG. 1. The so-called contact position is recognizable. The contact position is characterized in that now the forming head (roller head 23) is placed on the upper side of the sheet metal part 9 and the profile rollers 22 of the lower ring of cassettes 18 now begin to plunge into the inner circumference of the sheet metal part 9.

(31) FIG. 2 is followed in the next work step by FIG. 3, where it is recognizable that both the profile rollers 22 of the upper cassettes 17 and also the profile rollers 22 of the lower cassettes 18 have now plunged completely through the sheet metal part 9 and the profile rollers 22 of the lower cassettes 18 have already exited back out of the sheet metal part 9 to be formed. This means that the roller head 23 has now plunged into the central ring space 24 of the ring receptacle 10.

(32) In this method step, the stripper 14 would now be seated with its ring plate 13 on the formed sheet metal part 9, which is provided with the internal and external gear teeth, and will hold this part back while the upper tool 1 moves back upward.

(33) The removal of the sheet metal part which is thus formed is then performed according to FIG. 1 by the counter holder piston 7, which moves upward in the opposite direction to the arrow direction 27 and moves out the sheet metal part 9 upward, wherein FIG. 1 shows the position already moved out of the die 5.

(34) FIG. 4 shows an enlarged illustration of the structure of the roller head, wherein it is also indicated in conjunction with FIG. 1 that the roller head 23 is seated on the holder 11 and the holder is in turn received in a holding plate 12 (see FIG. 1). In the region of the holding plate 12 having a base plate 47 located above it, a central recess is provided, in which a crossbeam 15 is arranged, which is driven so it is movable by a pressure bolt 16 and which drives the stripper 14 with its ring plate 13 so it is displaceable.

(35) FIG. 4 therefore only shows the holder 11, while the remaining parts above the holder were described on the basis of FIG. 1.

(36) Two different working positions 36, 37 are provided, which assume a mutual distance 38 from one another, wherein a ring of cassettes 17, 18 arranged distributed uniformly on the circumference is provided on each working position 36, 37.

(37) The number of the cassettes 17, 18, which are arranged uniformly distributed on the respective circumference of the working positions 36 and 37, is dependent on the fineness and the indexing of the desired gear teeth in the sheet metal part 9.

(38) It is important in any case that each collar of cassettes 17, 18 is formed by an internal stop bushing 21, against the internal circumference and outwardly oriented circumference of which the respective back plates of the cassettes 17, 18 press. In this manner, the forming pressure which acts from the profile rollers 22 on the cassettes 17, 18 is transmitted via the cassette housing to the back plate and from there to the external circumference of the respective stop bushing 21.

(39) For this reason, the stop bushings 21 can be installed in a space-saving manner and absorb the entire forming load, whereby the small structure circumference of the roller head 23 results.

(40) The entire package of the lower indexing plate 20, the stop bushing 21 located in between, the upper indexing plate 35, and the upper stop bushing 21 is held together by the central fastening screw 19.

(41) FIG. 5 shows a first embodiment of a cassette 17, 18 for the roller head 23. The cassette is also illustrated in perspective on the basis of FIGS. 8 and 9.

(42) It substantially consists of a back plate 25, which is provided in the exemplary embodiment shown at a uniform thickness 45, which extends over the entire height of the cassette 17, 18.

(43) The back plate 25 is screwed together by means of fastening screws 28 with the housing 29 of the cassette.

(44) The front side of the cassette is formed by a closure plate 34, in which a front recess is provided, by which the profile of the axle-free profile roller 22, which is mounted so it is rotatable in the interior of the cassette, is received.

(45) Accordingly, a bearing surface 30, which encloses the outer circumference of the profile roller 22 and receives it in a formfitting manner, is provided in the interior of the cassette 17, 18. Lubricating grooves or other bearings (not shown in greater detail) can be provided.

(46) It can also be provided that the profile roller 22 is not received in an axle-free manner in the bearing surface of the recess in the interior of the cassette 17, 18, but rather that in this region the profile roller 22 is rotatably mounted with an axis in the cassette. It is also mounted so it is rotatable in the receptacle in the two arrow directions 32, and therefore on the bearing surface 30.

(47) In a third embodiment of the invention, it can be provided that instead of a profiled profile roller (an example of a profile is shown in FIGS. 8 and 9), a non-profiled profile roller is also provided. In a third embodiment, it can be provided that instead of the profile roller, an axle-free mounted ball or a rolling body (for example, a cylindrical rolling body) is provided, which rolls in a formfitting manner in the bearing surface 30.

(48) The receptacle in the cassette with the bearing surface 30 is selected in any case so that when the closure plate 34 is removed by loosening the fastening screws 28, the profile roller 22 can be removed and replaced.

(49) The rotational axis 31 is therefore only shown schematically, because it is an axle-free mounted profile roller 22.

(50) As described above, however, the profile roller 22 can also be received with a stub axle in the rotational axis 31 so it is rotatable in the cassettes 17, 18.

(51) FIG. 5 shows that a step-by-step adjustment of the forming depth can be performed in that the back plate 25 is provided as replaceable and, for example, can be replaced with a back plate 25 of greater thickness. In this case, if the thickness 45 of the back plate is increased, the forming depth of the profile roller 22 in the sheet metal part 9 is also increased.

(52) In another embodiment according to FIG. 5, which is shown with dashed lines, it can also be provided that the back plate 25 with its guide surface 26 is not applied in parallel to the movement direction in the arrow direction 27, but rather that this guide surface 26a is conical in the direction in relation to the working direction 27 of the cassette. This is symbolized by the guide surface 26a. In this case, during the movement of the cassette with the conically beveled guide surface 26a, a continuous change of the forming depth of the profile roller 22 would take place during the work stroke in the arrow direction 27.

(53) FIG. 6 shows, as an installation example, a cassette according to FIG. 5, as it presses with its guide surface 26 or 26a on a guide surface 46 oriented in the same direction (see FIG. 7).

(54) The guide surface 46 is formed in this case on the outer circumference of the respective stop bushing 21.

(55) FIG. 7 shows such an installation example, where it is recognizable that the rotationally-symmetrical stop bushing 21 is provided on the outer circumference with a plurality of stepped guide surfaces 46, on each of which the associated guide surfaces 26 are arranged in the region of the back plates 25 of the cassettes 17, 18.

(56) For securing in location, guide attachments 42 are formed on the base sides of the respective cassette, which are aligned in the radial direction and are guided so they are displaceable in associated radial grooves 40 of the indexing plate 20.

(57) In this manner, the cassettes 17, 18 are held so they are easily replaceable, on the one hand, on the base surface of the indexing plate 20 and, on the other hand, with their internal circumference on the external circumference of the stop bushing 21.

(58) FIGS. 8 and 9 show perspective views of the structure in each case of a cassettes 17 or 18. The same reference signs are used for the same parts according to FIG. 5.

(59) In FIG. 9, the closure plate 34 is removed in comparison to FIG. 8 solely for illustration. The profile rollers 22 are provided with arbitrary profile edges 33.

(60) The type of the profile edges is oriented according to the type of the desired gear teeth.

(61) FIG. 11 shows the combination example of a novel double roller head 23, 23a which substantially consists of a roller head 23 according to the above drawings and furthermore of a roller head 23a, as is described in principle in WO 2009/12 45 34 A2.

(62) The combination of two roller heads 23, 23a, of which one forming set operates from the inside to the outside in the roller head 23 and the other forming set operates from the outside to the inside in the roller head 23a, is heretofore not known from the prior art, however.

(63) Using this novel profile combination roller head 23, 23a, it is now possible for the first time to apply first gear teeth 51 on the outer circumference of a sheet metal part 9 and to apply second gear teeth 50 on the inner circumference of the same sheet metal part.

(64) It is not necessary for the solution in this case for the two roller heads 23, 23a to operate on the same plane; they can also, as a sequential tool, for example, first form the sheet metal part 9 oriented from the inside to the outside following one another in succession and in the second forming step then form the sheet metal part, which has already been formed from the inside to the outside, also subsequently from the outside to the inside.

(65) In a further embodiment, using the combination of the two roller heads 23, 23a, it is possible for the first time to provide a double-walled pot-shaped sheet metal part 9 on both coaxial circumferences 48, 49 with gear teeth 50, 51.

(66) Such a double-walled sheet metal part 9 is visible in FIGS. 10a-c, wherein the outer circumference 48 has gear teeth 51 and the inner circumference 49 has gear teeth 49. The gear teeth 51 were applied in this case by the roller head 23a and the gear teeth 49 were applied by the roller head 23

(67) For this purpose, as shown in FIG. 12, in one processing step a die 5a or another ring-shaped holder was inserted between the inner circumference 49 and the outer circumference 48 of the sheet metal part 9, wherein the profile rollers 23a, which are oriented radially from the outside toward the inside, apply first gear teeth 51 on the outer circumference 48 of the sheet metal part 9 and the die 5a, which presses against the inner circumference of the outer circumference 48, has complementary gear teeth 52a. The roller head 23a acts in this case with the profile rollers 22a on the outer circumference 48.

(68) In a similar manner, the profile rollers 22, which are oriented radially from the inside toward the outside, manufacture gear teeth 50 on the inner circumference 49 of the inner ring of the sheet metal part 9. The associated die 5a also has gear teeth 52 complementary to the gear teeth 50 here.

(69) The die 5a can also be a uniform ring-shaped part, which has the complementary gear teeth 52a on the outer circumference, and the complementary gear teeth 52 on the inner circumference. In this embodiment, the gear teeth 50, 51 can be produced on the double-walled workpiece 9 in a single work operation

(70) FIG. 13 shows an alternative embodiment to FIG. 1, which is characterized in that a deep-drawing tool leads the roll forming tool.

(71) The deep-drawing tool according to FIG. 13 substantially consists of the indexing plate 20, on the bottom side of which a forming edge 54 is implemented. To form the sheet metal part 9-1 shown in FIG. 13, firstly the indexing plate 20 is lowered into the inner cross-section of the sheet metal part 9-1, whereby the forming edge 54 is applied in a forming manner to the inner collar 53 of the approximately pot-shaped sheet metal part 9-1 and firstly cylindrically forms this collar 53. The indexing plate 20 with its forming edge 54 corresponds in function to a deep-drawing tool. Only after completed pressure forming using the deep-drawing tool does the roll forming tool follow with its profile rollers 22, which then ensure the gear teeth on the inner and/or outer circumference of the sheet metal part 9-1.

(72) This exemplary embodiment, in which a deep-drawing tool having a leading forming edge 54 firstly plunges into the internal circumference of the sheet metal part 9-1, can be used for all above-described embodiments.

LIST OF REFERENCE SIGNS

(73) 1 upper tool 2 lower tool 3 guide column 4 guide receptacle 5 die 5a 6 gear teeth (of 5) 7 counter holder piston 8 forming plate 9 sheet metal part 9-1 sheet metal part 10 ring receptacle 11 holder 12 holding plate 13 ring plate (stripper 14) 14 stripper 15 crossbeam 16 pressure bolt 17 cassette 18 cassette 19 fastening screw 20 indexing plate 21 stop bushing 22 forming body or profile roller 22a forming body or profile roller 23 forming body or roller head 23a forming body or roller head 24 ring space 25 back plate 26 guide surface 26a (of 17, 18) 27 arrow direction 28 screw 29 housing 30 bearing surface 31 rotational axis 32 arrow direction 33 profile edge 34 closure plate 35 indexing plate 36 working positions 37 working positions 38 distance 39 longitudinal bore hole (for 19) 40 radial groove 41 support 42 guide attachment 43 flange (of 9) 44 clamping plate 45 thickness (of 25) 46 guide surface (of 21) 47 base plate (of 1) 48 outer circumference 49 inner circumference 50 inner gear teeth 51 outer gear teeth 52 complementary gear teeth 52a (of 5a) 53 collar (inner side of 9) 54 forming edge (on 20)