U.S. patent number 3,654,790 [Application Number 05/037,855] was granted by the patent office on 1972-04-11 for means for making pulleys.
This patent grant is currently assigned to Philip L. Moskowitz, trustee. Invention is credited to Lester T. Zatko.
United States Patent |
3,654,790 |
Zatko |
April 11, 1972 |
MEANS FOR MAKING PULLEYS
Abstract
A pulley making method and apparatus for forming a pulley having
a pulley groove of given cross section defined by flange walls
connected through the root of the groove, the groove having a given
root diameter, from a pulley blank in the form of a sheet metal cup
having an annular bulge in the cup wall and an adjacent flaring
wall portion, with a valley defined between the bulge and adjacent
flaring wall portion. A pulley is formed from the blank by engaging
the flaring wall portion and the side of the bulge remote from the
valley with axially movable dies and moving the dies together to
crush the bulge and form it into a double wall. Groove-forming
rolls are positioned within the valley so that they extend radially
inwardly to an imaginary circle having a diameter equal to the root
diameter prior to the attainment of a final forming position by the
axially movable dies. Relative rotation is established between the
pulley blank and the group of rolls and the rolls roll within the
valley to receive the axial thrust of the bulge as its crushing is
completed, and to keep the valley clear as its shape approaches and
conforms to the desired pulley groove cross section.
Inventors: |
Zatko; Lester T. (Gates Hills,
OH) |
Assignee: |
Moskowitz, trustee; Philip L.
(N/A)
|
Family
ID: |
27181778 |
Appl.
No.: |
05/037,855 |
Filed: |
May 15, 1970 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
687695 |
Dec 4, 1967 |
|
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Current U.S.
Class: |
72/82;
29/892.3 |
Current CPC
Class: |
B21D
22/16 (20130101); B21D 53/26 (20130101); B21D
53/261 (20130101); F16H 55/44 (20130101); Y10T
29/4946 (20150115) |
Current International
Class: |
B21D
22/16 (20060101); B21D 22/00 (20060101); B21D
53/26 (20060101); F16H 55/36 (20060101); F16H
55/44 (20060101); B21d 022/16 () |
Field of
Search: |
;72/82,91,94 ;113/116D
;29/159,159.01 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Herbst; Richard J.
Parent Case Text
This application is a continuation of Ser. No. 687,695 filed Dec.
4, 1967, now abandoned.
Claims
I claim:
1. Method for forming a pulley having a pulley groove of given
cross section defined by flange wall means connected through the
root of the groove, the groove having a given root diameter,
comprising providing a pulley blank in the form of a sheet metal
cup having an annular bulge in the cup wall and an adjacent flaring
wall portion, with a valley defined between said bulge and adjacent
flaring wall portion, engaging said flaring wall portion and the
side of said bulge remote from said valley with axially movable
members and moving said members axially together to crush said
bulge and form it into a doubled wall, positioning a group of at
least two groove-forming rolls within said valley and extending
radially inwardly to an imaginary circle having a diameter equal to
the root diameter of the desired pulley groove and establishing
relative rotation between said group of groove-forming rolls and
said pulley blank at least while completing said crushing operation
with said rolls rolling within said valley to receive the axial
thrust of the bulge as its crushing is completed, to keep the
valley clear as its shape approaches and conforms to the desired
pulley groove cross section, and to form the pulley groove cross
section.
2. Method as in claim 1 in which the positioning of an assembly of
groove-forming rolls is accomplished by providing an assembly of a
pair of forming rolls spaced apart by the root diameter of the
desired pulley groove cross section, and translating said assembly
laterally into the work piece whereby said rolls tangentially
approach diametrically opposite sides of said valley.
3. Method as in claim 2 in which said assembly is allowed to float
transversely to its feed direction while it is translated into the
work piece.
4. Method as in claim 2 in which the rolls are allowed to float
along the axial direction while they are translated into the work
piece.
5. Method as in claim 4 in which the rolls are allowed to float
independently of each other.
6. Method as in claim 1 including providing pulley edge defining
shoulders on said groove-forming rolls and extending said shoulders
radially inwardly to imaginary circles of diameter corresponding to
the outside diameters of the sides of the desired pulley
groove.
7. Apparatus for forming a pulley having a pulley groove of given
cross section defined by flange wall means connected through the
root of the groove, the groove having a given root diameter, from a
pulley blank in the form of a sheet metal cup having an annular
bulge in the cup wall and an adjacent flaring wall portion, with a
valley defined between said bulge and adjacent flaring wall
portion, comprising axially movable members for engaging said
flaring wall portion and the side of said bulge remote from said
valley, means for moving said axially movable members together to
crush said bulge and form it into a doubled wall, a group of at
least two groove-forming rolls, means to move said groove-forming
rolls tangentially with respect to said cup to a position within
said valley so that said rolls extend radially inwardly to an
imaginary circle having a diameter equal to the root diameter of
the desired pulley groove, means to establish relative rotation
between said group of groove-forming rolls and said pulley blank at
least while completing said crushing operation so that said rolls
roll within said valley to receive the axial thrust of the bulge as
its crushing is completed, to keep the valley clear as its shape
approaches and conforms to the desired pulley groove cross section,
and to form the pulley groove cross section.
8. Apparatus according to claim 7 wherein said group of rolls
comprises an assembly of a pair of forming rolls spaced apart by
the root diameter of the desired pulley groove cross section, and
wherein said means to move said forming rolls translates said
assembly laterally into the work piece, whereby said rolls
tangentially approach diametrically opposite sides of said
valley.
9. Apparatus according to claim 8 in which said assembly is
provided with means permitting floating transverse to its direction
of feed while it is translated into the work piece.
10. Apparatus according to claim 8 wherein said assembly includes
means permitting axial floating of the rolls as they are translated
into the work piece.
11. Apparatus according to claim 10 wherein the rolls axially float
independently of each other.
12. Apparatus according to claim 7 wherein said groove-forming
rolls are provided with pulley edge defining shoulders and wherein
said shoulders extend radially inwardly to imaginary circles of
diameters corresponding to the outside diameters of the sides of
the desired pulley groove when said rolls are moved within said
valley.
13. Apparatus for forming a circular article from sheet metal
comprising axially opposed first and second die means, pressure
means to move at least one of said first and second die means so
that the die means are moved together toward a final apposition at
which they define a die cavity corresponding to portions of the
ultimate cross section of the article to be formed, forming means
cooperating with said first and second die means to form remaining
portions of said ultimate cross section encompassing said
first-named portions, said remaining portions of the ultimate cross
section being radially outward of said first-named portions, said
forming means comprising roll die means, said roll die means
comprising an assembly of a pair of forming rolls spaced apart by
the minimum outside diameter of said remaining portions of said
ultimate cross section, means to drive at least one of said die
means to establish relative rotative movement between the roll die
means and an article being formed, means to advance said roll die
means to a position forming said remaining portions of said
ultimate cross section of the article prior to the attainment of
said final apposition of said first and second die means, said roll
advancing means being adapted to translate said assembly laterally
into the article, whereby said rolls tangentially approach
diametrically opposite sides of said remaining portions of said
ultimate cross sections.
14. Apparatus according to claim 13 in which said assembly is
provided with means permitting transverse floating in its feed
direction while it is translated into the work piece.
15. Apparatus according to claim 13 wherein said assembly includes
means permitting axial floating of the rolls as they are translated
into the work piece.
16. Apparatus according to claim 15 wherein the rolls float
independently of each other.
17. Apparatus according to claim 13 wherein said article is
circular, and said roll die means are provided with shoulders which
define part of the said remaining portions of said ultimate cross
section.
18. Apparatus for forming a pulley having a body portion and having
a pulley groove of given cross section extending circumferentially
around said body portion and defined by first and second flange
wall means connected through the root of the groove, the groove
having a given root diameter, from a pulley blank in the form of a
sheet metal cup having an annular bulge in the cup wall and an
adjacent flaring wall portion, with a valley defined between said
bulge and adjacent flaring wall portion, comprising a frame, an
axially rotatable lower die mounted on said frame, an axially
rotatable upper die axially aligned with said lower die, ram means
for said dies, drive means for rotatively driving at least one of
said upper and lower dies, said upper and lower dies having
surfaces which, when moved together, define and form the body
portion of the pulley, a roller assembly slidable on said frame
toward the locus of said upper and lower dies when they approach
closed position, said roller assembly comprising a pair of rollers
having upper and lower edge surfaces which respectively define
(with portions of the upper and lower dies respectively) said first
and second flange wall means, means to advance said assembly toward
said locus so that said roller edges enter said valley, said
advancing means moving said assembly so that said rollers enter
said valley prior to the complete formation of the body portion of
the pulley by the upper and lower dies, said roller assembly
further comprising means mounting said rollers so that the
periphery-to-periphery distance between said rollers is fixed and
corresponds to said given root diameter.
19. Apparatus as in claim 18, said roller mounting means being
pivoted with respect to said frame.
20. Apparatus for forming a pulley having a pulley groove of given
cross section defined by flange wall means connected through the
root of the groove, the groove having a given root diameter, from a
pulley blank in the form of a sheet metal cup having an annular
bulge in the cup wall and an adjacent flaring wall portion, with a
valley defined between said bulge and adjacent flaring wall portion
comprising a frame, axially opposed first and second die means on
said frame, first translator means having output means for
advancing at least one of said first and second die means so that
the die means are translated together toward a final forming
position which defines a die cavity corresponding to portions of
the ultimate cross section of the article to be formed, forming
means on said frame cooperating with said first and second die
means to form remaining portions of said ultimate cross section,
said forming means comprising a group of two roller dies, second
translator means having output means for advancing said forming
means to a position forming said remaining portions of the ultimate
cross section of the pulley, both said first and second die means
having less than three degrees of freedom with respect to the
frame, at least one of said first and second die means having more
than zero degrees of freedom with respect to the frame, said at
least one die means having zero degrees of freedom with respect to
said output means of said first translator means, said group of two
roller dies having three degrees of freedom with respect to the
frame and two degrees of freedom with respect to the output end of
said second translator means, said roller dies having less than two
degrees of freedom with respect to each other during the forming
operation and having their axes fixed with respect to each other to
establish the desired root diameter.
21. Apparatus as in claim 20, said roller dies having one degree of
freedom with respect to each other.
22. Apparatus for forming an article from sheet metal, comprising
axially opposed first and second die means, pressure means to move
at least one of said first and second die means so that the die
means are moved together toward a final apposition at which they
define a die cavity corresponding to portions of the ultimate cross
section of the article to be formed, forming means cooperating with
said first and second die means to form remaining portions of the
ultimate cross section encompassing said first-named portions, said
forming means comprising roll die means, means to drive at least
one of said die means to establish relative rotative movement
between the roll die means and an article being formed, means
advancing said roll die means to a position wherein prior to the
attainment of said final apposition of said first and second die
means said roll die means forms said remaining portions of said
ultimate cross section of the article.
23. Method for forming an article from a blank in the form of a
metal cup comprising the steps of providing a metal cup,
positioning said cup between axially opposed first and second die
means, moving at least one of said first and second die means so
that the die means are moved together toward a final apposition at
which they define a die cavity corresponding to portions of the
ultimate cross section of the article to be formed, providing
forming means cooperating with said first and second die means to
form remaining portions of said ultimate cross section encompassing
said first-named portions, said forming means comprising roll die
means, establishing relative rotative movement between the roll die
means and the metal cup, and advancing said roll die means to a
position forming said remaining portions of the ultimate cross
section of the article prior to the attainment of said final
apposition of said first and second die means.
Description
BACKGROUND OF THE INVENTION
Single or multiple V-groove pulleys have been and are
conventionally formed from stamped sheet metal by first performing
a cupping operation, providing an outwardly flared end portion on
the cup and then providing at least one circumferential fold of the
cup which defines a pulley groove with the outwardly flared end
portion of the cup or a second pulley groove with an adjacent
circumferentially folded portion of the cup.
In order to form such circumferentially folded cup wall portions,
techniques have been proposed which involve axially restraining a
sheet metal cup having a cylindrical side wall between a headstock
spindle and a tailstock spindle. A mandrel assembly which comprises
a multiplicity of radially extending fingers is positioned within
the cup between the headstock spindle and the tailstock spindle.
The cylindrical side wall of the cup is then deformed radially
inwardly by engaging the cylindrical side wall with rollers to form
valleys in the side wall between the open end of the cup and the
mandrel assembly and between the mandrel assembly and the closed
end of the cup. During this rolling operation, the headstock and
tailstock spindles are rotated and moved together to form the
desired V-grooves in the pulley as the forming rolls are moved
radially inwardly.
According to such prior art techniques, the headstock and tailstock
spindles are moved together to their final forming positions prior
to or simultaneous with the attainment of the ultimate radially
inward movement of the forming rolls.
Pulleys formed according to this prior art techniques are
drastically worked and may be stretched or thinned by such working
operations, thereby creating zones or areas of weakness in the
pulleys.
Other prior art techniques involve the formation of V-grooves on
the side wall of the pulley by press-forming operations wherein a
multiplicity of dies are brought together to form the ultimate
pulley configuration. The dies are moved against a cup-shaped
pulley blank and those dies are moved by mechanical linkages to a
predetermined final position. Frequently, however, the metal
forming the cup blank varies in wall thickness as a result of the
cupping operation or because of variations in thickness of the
as-received sheet stock, so that close tolerances in the final
product or use of minimum-gage material cannot be accomplished
without using costly close-tolerance sheet stock or running into
unacceptable die breakage.
In many of these prior art techniques, a pulley hub is brazed onto
the formed pulley. Since the brazing operation is conducted at a
relatively high brazing temperature, the pulley may be distorted as
the working stresses are relieved. After the brazing operation, the
pulley must be checked for any distortion and, if necessary,
reworked.
Generally, separate final finishing in a rolling operation with
finish rolls is necessary in many prior art methods.
The forming process and apparatus according to this invention
overcome prior art pulley-forming problems such as those mentioned,
simplify the prior art steps in making the pulley, and produce a
finished pulley having an accurately located center hub or
connecting aperture.
These and other features, advantages, and objects of the invention
will become more readily apparent and more fully understood from
the following detailed description of the invention and from the
accompanying drawings.
In the drawings:
FIG. 1a is a cross-sectional, elevational view of a cup after
blanking, drawing, and piercing operations.
FIG. 1b is a cross-sectional, elevational view of a cup according
to a further aspect of this invention, showing the cup after
blanking and drawing operations.
FIG. 2a is a cross-sectional, elevational view of the cup
illustrated in FIG. 1a after further mechanical working
operations.
FIG. 2b is a cross-sectional, elevational view of the cup
illustrated in FIG. 1b after further mechanical working
operations.
FIG. 3a is a cross-sectional, elevational view of the cup
illustrated in FIG. 2a showing the cup in the form of a pulley
blank after still further mechanical working operations have been
performed and showing a hub brazed on the cup.
FIG. 3b is a cross-sectional, elevational view of the cup
illustrated in FIG. 2b showing the cup in the form of a pulley
blank after still further mechanical working operations have been
performed.
FIG. 4a is a cross-sectional, elevational view of the pulley blank
illustrated in FIG. 3a being formed in accordance with the method
according to this invention.
FIG. 4b is a cross-sectional, elevational view of the pulley blank
illustrated in FIG. 3b being formed in accordance with the method
of this invention.
FIG. 5a is a cross-sectional, elevational view of a completed
pulley formed according to one aspect of the present invention and
associated forming dies.
FIG. 5b is a cross-sectional, elevational view of a completed
pulley formed in accordance with a further aspect of this invention
and associated forming dies.
FIG. 6 is a fragmentary front elevational view partly in section of
a pulley forming machine according to this invention.
FIG. 7 is a cross-sectional plan view of the apparatus illustrated
in FIG. 6, the plane of the view being indicated by the line 7--7
in FIG. 6.
FIG. 8 is a fragmentary cross-sectional view of the apparatus, the
plane of the section being indicated by the line 8--8 in FIG.
7.
FIG. 9 is an enlarged, fragmentary, cross-sectional view, the plane
of the section being indicated by the line 9--9 in FIG. 7.
FIG. 10 is a schematic hydraulic circuit diagram of controls for
the apparatus.
Referring now to the drawings, and particularly to FIGS. 1a, 2a,
3a, 4a, and 5a, a cup blank 10 is illustrated. In the condition
illustrated in FIG. 1a, the cup 10 has been punched from flat sheet
stock and drawn into a cup having a radially extending flange 11.
The cup is also pierced to provide an axial bore 12. The cup is
then formed into the condition illustrated in FIG. 2a by forming a
rim 13 on the flange 11 and extruding the bore 12 to provide an
annular lip 14 on the top of the cup. As may be seen in FIG. 3a,
the cup 10 is then provided with a hub 15 which is brazed within
the lip 14. As will become apparent, any distortion caused by the
brazing operation is corrected during subsequent forming
operations, since the axis of the pulley hub is employed as a
working axis.
The side wall is provided with a bulge 16 by, for example, the
technique set forth in U.S. Pat. No. 2,929,345. The bulge 16 and
the flange 11 define a circumferentially extending valley 17. The
form of the cup 10 illustrated in FIG. 3a comprises a pulley blank
20 which is formed into a pulley in accordance with the teachings
of this invention.
As may be seen in FIG. 4a and as will be explained in greater
detail, the flange 11 of the pulley blank 20 and the side of the
bulge 16 remote from the valley 17 are respectively engaged with
axially movable members 21 and 22. When the axially movable members
21 and 22 have been moved together to the position illustrated in
FIG. 5a, the bulge 16 is crushed and formed into a doubled wall 23.
During the axial movement of the members 21 and 22, the pulley
blank 20 is rotated about the axis of the pulley hub 15 and a group
of at least two groove-forming rolls 24 and 25 are positioned
within the valley 17 so that they extend radially inwardly to an
imaginary circle having a diameter equal to the root diameter of
the desired pulley groove. The rolls 24 and 25 roll within the
valley 17 to receive the axial thrust of the bulge 16 as it is
formed into the doubled wall 23. The rolls 24 and 25 keep the
valley 17 clear as its shape approaches and conforms to the desired
pulley groove cross-section which is defined by the cross-section
of the rolls 24 and 25.
Referring now to FIGS. 1b, 2b, 3b, 4b, and 5b, a pulley is formed
according to a further aspect of this invention. A cup 30 is
illustrated in FIG. 1b. The cup 30 is blanked and drawn to provide
an outwardly flaring flange 31. The cup 30 is further formed to the
condition illustrated in FIG. 2b by providing a downwardly
extending rim 33 on the flange 31.
As is shown in FIG. 3b, the cup 30 is then provided with a bulge 36
which defines a valley 37 with the flange 31. The form of the cup
illustrated in FIG. 3b comprises a pulley blank 40 which is formed
into a pulley in accordance with one aspect of this invention.
As may be seen in FIG. 4b, the flange 31 and the side of the bulge
36 remote from the valley 37 are respectively engaged by axially
movable members 41 and 42 respectively. The axially movable members
41 and 42 are moved together to crush the bulge 36 and form it into
a doubled wall 43. During the axial movement of the members 41 and
42, the pulley blank 40 is rotated about its axis and a group of at
least two groove-forming rolls 44 and 45 are positioned within the
valley 37 so that they extend radially inwardly to an imaginary
circle having a diameter equal to the root diameter of the desired
pulley groove.
The rolls 44 and 45 roll within the valley 37 to receive the axial
thrust of the bulge 36 as its crushing is completed. The rolls 44
and 45 keep the valley 37 clear as its shape approaches and
conforms to the desired pulley groove cross section. During the
final stages of the forming operation on the pulley blank 40, an
aperture 46 is punched in the blank 40 by a punch member 47 which
is provided in the axially movable member 42. The punch member
accurately establishes the location of aperture 46 so that the axis
of the aperture corresponds to the axis of the formed pulley.
Referring now to FIG. 6, a forming machine 50 is illustrated. The
embodiment of the machine 50 illustrated in FIG. 6 is intended to
form a pulley from the pulley blank 20 illustrated in FIG. 3a. It
is to be understood, however, that the machine 50 may be adapted to
perform such an operation on the pulley blank 40 by providing one
of the axially movable members with a center punch to form the
aperture 46 in that pulley blank.
The machine 50 includes a frame having a bed assembly 51, side
frame members 52 and 53, and a top crosspiece 54 connected to the
side frame members 52 and 53.
The bed 51 may include a slide 55 having a depending plate portion
56. The plate portion 56 is connected to a ram 57 of a
double-acting hydraulic cylinder 58. The cylinder 58 is fixed at
one end to the side frame 52 and drives the slide 55 from the
position illustrated in dotted outline in FIG. 6 to the position
illustrated in phantom outline in that Figure.
The slide 55 carries a pair of bottom die means 59 on its upper
surface. Each die means 59 comprises a die block 60 which is fixed
to a driving member 61. The driving member 61 is fixed to a plate
62 which is driven by a drive shaft 63. The drive shaft 63 has a
relatively large upper portion 64 connected to the plate 62 and to
a bearing plate 65 which is rotatable on bearings 66. The drive
shaft 63 further includes a relatively small portion 67 which
extends through the slide 55 and is journaled by bearings 68. A
motor 69 drives the shaft 63, the bearing plate 65, the plate 62,
the driving member 61, and the die block 60 about their cylindrical
axes.
Each die block 60 has one degree of freedom with respect to the
machine frame. If a machine is provided with a single die block 60
however, a die block 60 may have either one degree of freedom (a
single die block 60 mounted on the slide 55), or zero degrees of
freedom (a single die block 60 fixed to a non-movable bed 51).
In axial alignment with the die 60 is a die 70. The die 70 is fixed
to a cylindrical block 71 which is rotatably mounted in a bearing
assembly 72. The bearing assembly 72 is fixed to a plate 73 which
is mounted at one end of a first translator means which includes a
ram 74 and a double-acting power cylinder 75 which is fixed to the
top crosspiece 54. The ram 74 and its associated elements comprise
output means for advancing the die 70 so that the die 70 and the
die block 60 are translated together toward a final forming
position which defines a die cavity corresponding to portions of
the ultimate cross section of the article to be formed.
The die 70 and the die block 60 may both move to a final forming
position, if desired, by providing a translator means for the die
block 60. The invention therefore includes at least one of the dies
60 and 70 having more than zero degrees of freedom with respect to
the frame. In the illustrated embodiment, the die 70 has one degree
of freedom with respect to the frame (axial), and the die block 60
has one degree of freedom with respect to the frame (lateral). The
die 70 has zero degrees of freedom with respect to the output end
of the first translator means. Taken together, the die 70 and the
die block 60 have less than three degrees of freedom with respect
to the frame.
The machine 50 further includes a forming means 76 which comprises
a group of at least two groove-forming rolls 24 and 25. The rolls
24 and 25 are rotatably mounted on spindles 79 and 80 which are
fixed laterally with respect to each other so that the edge-to-edge
distance between the rolls 24 and 25 extend radially inwardly to an
imaginary circle having a diameter equal to the root diameter of
the desired pulley groove. The spindles 79 and 80 are slidably
mounted in lower blocks 81 and 82 and are urged to a normal
position illustrated in FIG. 6 by springs 83. The upper ends of
each spindle 79 and 80 are slidably received by upper blocks 84 and
85 so that the spindles 79 and 80 and their rolls 24 and 25 are
axially floatable with respect to each other and with respect to
the bed 51 and so that the rolls 24 and 25 have less than two
degrees of freedom with respect to each other.
As may be seen most clearly in FIGS. 7 and 8, the upper and lower
blocks 81, 82, 84, and 85 are mounted at the ends of arms 86 and
87. The arms 86 and 87 are adjustably fixed to a crossbar assembly
88. The arms 86 and 87 may be adjusted relative to each other by
adjusting screws 89 and 90 respectively so that the desired root
diameter may be precisely established and maintained. The crossbar
assembly 88 has plates 91 which are fixed to and separated by a
spacing cylinder 92.
The cylinder 92 is pivotally connected to a shaft 93 which is fixed
to a crossplate 94. The crossplate 94 is fixed at its ends to
sleeves 95 and 96, which are slidably mounted on guide rods 97 and
98. The guide rods 97 and 98 are mounted parallel to each other by
mounting blocks 99 which are fixed to the bed 51.
A strap 100 extends downwardly from the crossplate 94 and is
connected to a second translator means which includes one end of a
power ram 101 and an associated double-acting cylinder 102. The
cylinder 102 drives the ram 101 and, therefore, the assembly
comprising the shaft 93, the cylinder 92, the plates 91, the
crossbar assembly 88, the arms 86 and 87, and the rolls 24 and 25
from the retracted position illustrated in FIGS. 7, 8, and 9 to an
extended position wherein the rolls 24 and 25 have diameters which
are aligned with diameters of the dies 60 and 70. The ram 101
comprises output means for advancing the rolls 24 and 25 to form
remaining portions of the ultimate cross section of the article to
be formed.
The rolls 24 and 25 as a group have three degrees of freedom with
respect to the frame and two degrees of freedom with respect to the
output end of the second translator means.
OPERATION
A pulley blank, such as the pulley blank 20, is positioned on the
die 60 which is dwelling at one side of the working station of the
machine. The pulley blank 20 is mounted on the die 60 so that a
guide pin 105 extends through the hub 15. Referring now to FIG. 10,
a working cycle is initiated by actuating a switch 106 which
energizes a four-way solenoid-operated valve 108. When the valve
108 is energized, the piston chamber of the cylinder 58 is
connected to a source of fluid pressure 109 so that the ram 57
drives the slide 55 to the right as viewed in FIG. 6. The blank 20
is then positioned below the die 70.
When the slide 55 reaches the end of its travel, a limit switch 110
is operated to energize a timer 111 which actuates a four-way valve
112. The timer 111 remains energized through a predetermined work
cycle. When the four-way valve 112 is reversed, the piston chamber
of the power cylinder 75 is connected to the source of fluid
pressure 109 through a line 113. The ram 74 and its die 70 are
driven downwardly toward the die 60 to perform the pulley-forming
operation. During the downward travel of the ram 74, a limit switch
114 is actuated to energize the motor 69, which rotates the die 60
that has been brought into axial alignment with the die 70. To
prevent the operation of the other motor 69, suitable
position-responsive lock-out means (not shown) may be provided to
prevent the operation of the motor 69, which is dwelling at a
loading station. The switch 114 is energized prior to engagement of
the blank 20 by the upper die 70 so that upon engagement of the
blank 20 by that die, the die 70 is rotated.
As the die 70 progresses downwardly, the bulge 16 is crushed to
form the doubled wall 23. Prior to the completion of this crushing
operation, however, and particularly prior to the time when metal
would be displaced into the valley 17, the forming rolls 24 and 25
are advanced into the valley 17 in the following manner. Either
prior to engagement of the blank 20 by the die 70, or at least
prior to the time when metal would be forced into the valley 17, a
limit switch 115 is operated by the ram 74. When the limit switch
115 is operated, a four-way valve 116 is operated to connect the
piston chamber of the cylinder 102 to the source of fluid pressure
109 through a line 117. The rolls 24 and 25 are driven forwardly
until they enter the valley 17.
The crushing operation is completed when the rolls 24 and 25 are
within the valley so that the rolls roll within the valley to
receive the axial thrust of the bulge 16 as its crushing is
completed to form the doubled wall 23. The rolls 24 and 25 keep the
valley clear as its shape approaches and conforms to the desired
pulley groove cross section. The rolls 24 and 25 are provided with
pulley edge defining shoulders 24a and 25a which extend radially
inwardly with respect to the pulley to imaginary circles of
diameter corresponding to the outside diameters of the sides of the
desired pulley groove.
As was previously indicated, the rolls 24 and 25 are laterally
fixed with respect to each other, but are pivoted together from the
shaft 93. The rolls are axially movable in their blocks 81, 82, 84,
and 85. Any eccentricity caused by, for example, variations in the
thickness of the as-received sheet stock or variations in the
thicknesses caused by the drawing operation are corrected by the
rolls 24 and 25. Any excessive thickness in the stock which is
encountered by a roll 24 or 25 will cause that roll to ride toward
the axis of rotation of the pulley blank to correct such a
variation in thickness. The rolls 24 and 25 may tend to pivot
together during initial valley contact but after that interval, the
forming rolls 24 and 25 will provide a pulley groove having its
center of rotation at the rotational axis of the pulley blank.
After the timer 111 indicates the completion of a working cycle,
the valve 112 is returned to the position illustrated in FIG. 10 to
retract the ram 74 and thereby raise the die 70. As the ram 74 is
retracted, the limit switch 115 is again actuated to return the
valve 116 to the position illustrated in FIG. 10. The rolls 24 and
25 are retracted. Further upward travel of the ram 74 trips the
switch 114 to stop the operation of the operating motor 69.
During the foregoing forming operation, a completed pulley has been
removed from the loading station and a pulley blank is loaded onto
the die 60 which is dwelling at the loading station. When the ram
74 reaches the upward limit of its stroke, therefore, the cycle may
be repeated by actuation of the switch 106.
The invention is not restricted to the slavish imitation of each
and every detail set forth above. Obviously, techniques and devices
may be devised which change, eliminate, or add certain specific
details without departing from the scope of the invention.
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