U.S. patent number 3,803,890 [Application Number 05/227,799] was granted by the patent office on 1974-04-16 for rolling machines.
This patent grant is currently assigned to National Research Developement Corporation. Invention is credited to Gordon Sydney Connell.
United States Patent |
3,803,890 |
Connell |
April 16, 1974 |
ROLLING MACHINES
Abstract
This invention relates to improvements in rolling machines and
methods of forming initially cylindrical workpieces to shape. The
workpiece is initially located along its axis relative a pair of
forming members and then rolled to shape, at least one of which has
a profile to be squeezed into the workpiece. The forming member or
members having the profile have radially outwardly diverging
flanges at their edges to control the shape of the edges of the
cylindrical workpiece and determine width-wise spread. Where the
workpiece is rotatably fitted over a mandrel and at least two
forming members are spaced evenly around the workpiece, a number of
rotatably supported growth control rolls are spaced around the
workpiece, arranged to remain in contact therewith during rolling
in peripheral regions between the forming rolls and prevented from
retracting during rolling so avoiding substantially deformation of
the workpiece from the circular and preventing undue metal
fatique.
Inventors: |
Connell; Gordon Sydney
(Cheltenham, EN) |
Assignee: |
National Research Developement
Corporation (London, EN)
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Family
ID: |
27447421 |
Appl.
No.: |
05/227,799 |
Filed: |
February 22, 1972 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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102380 |
Dec 29, 1970 |
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Foreign Application Priority Data
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Dec 31, 1969 [GB] |
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63607/69 |
Feb 22, 1971 [GB] |
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5132/71 |
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Current U.S.
Class: |
72/107; 72/108;
29/898.066 |
Current CPC
Class: |
F16C
33/64 (20130101); B21H 1/12 (20130101); Y10T
29/49689 (20150115) |
Current International
Class: |
B21H
1/00 (20060101); B21H 1/12 (20060101); B21h
001/12 () |
Field of
Search: |
;72/366,102,107,108,110
;29/148.4R |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Larson; Lowell A.
Attorney, Agent or Firm: Cushman, Darby & Cushman
Parent Case Text
This application is a continuation-in-part of my copending
application Ser. No. 102,380 filed on Dec. 29, 1970 now abandoned.
Claims
I claim:
1. A method of forming to shape an initially cylindrical workpiece
comprising initially locating said cylindrical workpiece along its
cylindrical axis relative to a pair of forming members at least one
of which is a forming roll having a profile to be squeezed into
said workpiece, and then rolling and squeezing said workpiece
between said pair of forming members to impress in said workpiece
by metal flow said profile, at least said forming roll having said
profile to be squeezed into said workpiece having radially
outwardly diverging flanges at its edges which during said rolling
step controls the shape of the edges and the width-wise spreading
of said workpiece, said flanges being angled at an angle of up to
15.degree. to the normal to the axis of rotation of said roll.
2. A method according to claim 1 in which said workpiece is mounted
between opposed spring means to locate it relative to said forming
rolls before being formed to shape.
3. A method according to claim 1 in which a profile is rolled into
the outer facing surface of said workpiece, said workpiece being
rotatably supported on a mandrel and said profile being impressed
into the outer facing surface of said workpiece by said profiled
forming roll.
4. A method according to claim 3 in which said profile is squeezed
into said outer facing surface of said workpiece by a pair of
diametrically opposed profiled forming rolls.
5. A method according to claim 1 in which a profile is rolled into
the inner facing surface of said workpiece by squeezing said
workpiece between an inner profiled forming roll positioned within
the workpiece and an outer cylinder within which said workpiece is
positioned.
6. A machine for rolling a workpiece to a desired shape comprising
a rotatable mandrel over which said workpiece is to fit so as to be
supported by said mandrel during rolling, at least two heads evenly
angularly spaced around the periphery of the workpiece, each head
being capable of carrying a driven forming roll shaped to roll the
workpiece to the desired shape and being constrained so that said
rolls are movable relative to the workpiece in a direction radially
of said workpiece so that said workpiece is shaped by being
squeezed by the forming rolls, location means for initially
locating the workpiece along it axis relative to said forming
rolls, and a number of rotatably supported growth control rolls
which are spaced around said workpiece, are arranged to remain in
contact with the workpiece during rolling in peripheral regions
between said forming rolls, and are arranged to be prevented from
retracting during rolling so avoiding substantial deformation of
said workpiece from the circular and preventing undue metal
fatigue.
7. A machine according to claim 6 in which said growth control
rolls are arranged to be urged against said workpiece during
rolling by means of hydraulic rams which maintain the growth
control rolls in contact with said workpiece and which are arranged
to prevent said growth control rolls from retracting during
rolling.
8. A machine according to claim 6 in which said growth control
rolls have a form which is the same as that on said forming
rolls.
9. A machine according to claim 6 in which said growth control
rolls have a form which is similar to that on said forming
rolls.
10. A machine according to claim 6 in which said growth control
rolls are resiliently movable in a direction along their rotational
axes.
11. A machine according to claim 6 which has a pair of
diametrically opposed heads arranged to carry said forming rolls
and a pair of diametrically opposed growth control rolls spaced at
90.degree. with respect to said forming rolls.
12. A process for rolling a workpiece to a desired shape using a
machine according to claim 6 in which said workpiece is initially
located along its axis by said location means, is then squeezed by
said forming rolls sufficiently to indent the workpiece to start
the shaping of said workpiece and form a location for said growth
control rolls and thereafter said workpiece is contacted by said
growth control rolls, said growth control rolls contacting said
workpiece with a force sufficient to prevent substantial
deformation from the circular between the forming rolls but
insufficient to cause substantial forming of said workpiece and,
after said workpiece has been rolled to the desired shape, and
forming rolls and said growth control rolls all start retracting at
the same time.
13. A process according to claim 12 in which said workpiece has an
outside diameter of up to 4 inches.
14. A process according to claim 12 in which said forming rolls
advance at a rate of from 0.010 to 0.020 inch per revolution of the
workpiece.
15. A machine for rolling a workpiece to a desired shape
comprising:
a rotatable mandrel having an axis, said mandrel being capable of
rotatably supporting said workpiece,
a pair of heads arranged diametrically opposite one another
relative said axis of said mandrel, said heads being constrained to
move in the radial direction relative said axis of said
mandrel,
a forming roll rotatably supported by each head, said roll having a
forming profile to be squeezed into said workpiece, and radially
outwardly diverging flanges at its edges, said flanges diverging at
an angle of up to 15.degree. to the normal to the axis of rotation
of said roll,
hydraulic ram means for progressively and substantially equally
advancing said heads so as to squeeze and form said workpiece to
shape, a pair of rotatably supported growth control rolls arranged
diametrically opposite one another and at 90.degree. to said
forming rolls,
hydraulic ram means for urging said growth control rolls in contact
with said workpiece during rolling and substantially preventing
retraction of said growth control rolls during rolling, and opposed
spring means on said mandrel between which said workpiece is
arranged to be held prior to and during rolling so as initially to
locate said cylindrical workpiece along its axis relative said
forming rolls.
16. A method of forming to shape an initially cylindrical workpiece
comprising initially locating said cylindrical workpiece along its
cylindrical axis relative to a pair of forming members at least one
of which is a forming roll having a profile to be squeezed into
said workpiece, at least said forming roll having said profile to
be squeezed into said workpiece including radially outwardly
diverging flanges at its edges, said workpiece being positioned
equidistant from said inclined flanges of said workpiece, holding
said workpiece in said initial location, and rolling and squeezing
said workpiece between said pair of forming members to impress in
said workpiece by metal flow said profile, wherein said outwardly
diverging flanges of said forming roll controls the shape of the
edges and the width-wise spreading of said workpiece during said
rolling step and wherein said workpiece follows the contour of the
flanges but does not fill the nip between the opposed forming
rolls, said flanges being angled at an angle of up to 15.degree. to
the normal to the axis of rotation of said roll.
Description
This invention relates to improvements in rolling machines and is
particularly concerned with machines in which metal workpieces or
blanks are formed to shape by being rolled under pressure. In
particular the invention relates to rolling machines which are
eminently suited for forming bearing rings from plain cylindrical
workpieces.
BACKGROUND OF THE INVENTION
When a workpiece is rolled to shape it is squeezed between two
forming members which press into the workpiece a shape dictated by
the profile of the forming members. In this way excellent profiled
workpieces can be made. It has not been possible, however, to
ensure that the profile is consistently positioned on the
workpieced with the result that from a production run one can not
be sure of achieving a series of rolled workpieces which are
identical with one another.
THE INVENTION
Therefore according to the invention there is provided a method of
forming to shape an initially cylindrical workpiece in which the
cylindrical workpiece is initially located along its axis relative
to a pair of forming members one or both of which are forming rolls
having a profile to be squeezed into the workpiece, and is then
rolled and squeezed between the pair of forming members to impress
in the workpiece the profile, the forming roll or rolls having
radially outwardly diverging flanges at their edges which control
the shape of the edges of the workpiece and determine the
width-wise spread of the workpiece during rolling, and these
flanges on the roll or rolls being angled at an angle of up to
15.degree. to the normal to the axis of rotation of the roll.
By angling the flanges at an angle of up to about 15.degree. to the
normal to the axis of rotation of the rotation of the roll, this is
found to reduce or eliminate scuffing and slivering of the side
faces of the workpiece so avoiding small pieces of metal rolling
into the surface being rolled, so damaging it. This angling of
these flanges also gives a better flow of metal.
By using rolls such as these one can roll workpieces accurately to
shape and each rolled workpiece of a production run will be
identical with one another since one can ensure that the profile
given to the workpiece is accurately positioned relative to the
workpiece.
Provided one starts with a cylindrical workpiece of known volume,
the side flanges on the roll or rolls control the width-wise spread
of the workpiece during rolling and, after filling the width of the
profiled roll, the metal in the workpiece flows so as to start to
travel up the sides of the flanges. Because these are angled at no
more than a small angle to the normal to the axis of rotation of
the roll, the final overall width of the rolled workpiece is only
dependent to a very small degree upon the extent to which metal has
flowed up the side edges of the flanges. The degree of this flow
can be controlled fairly accurately by controlling the time of
rolling. Therefore the rolled workpiece has an accurately known
width and the impressed profile is accurately spaced in relation to
the side edges. Therefore, when effecting any further process steps
on the rolled workpiece, e.g., grinding, one can determine the
location of the rolled workpiece by means of its side edge and in
so doing accurately locate the rolled profile.
Usually the formed workpiece is heat treated and then finally
ground to exact size. It is found that, after rolling according to
the invention, relatively little distortion of the formed workpiece
occurs during this heat treatment, and a smaller amount of material
needs to be removed in the ensuing grinding step to give the
finished accurate bearing ring then in the case where the bearing
ring is formed by conventional machinery followed by grinding.
In addition, because rolling to shape does not involve the removal
of material, bearing rings can be made from less stock material as
compared with conventional machining to shape.
Bearing rings can therefore be produced more economically according
to the invention than by conventional machining.
The workpiece is initially located along its axis in relation to
the roll or rolls. This can be achieved for example, quite simply
by resiliently holding the workpiece between opposed spring means.
The pressure exerted by these spring means then automatically
centres the workpiece in relation to the forming roll or rolls and
ensures that the width-wise spread of the workpiece is consistent
from workpiece to workpiece.
The invention is applicable to the case where a profile is rolled
into the outer facing surface of a workpiece in which case the
workpiece can be rotatably supported on a mandrel and rolled
between, for example, a pair of profiled forming rolls, and also
the case where a profile is rolled into the inner facing surface of
a workpiece in which case the workpiece is squeezed between an
inner profiled forming roll and an outer cylinder.
All corners on the forming part of the forming roll or rolls should
have the maximum radius possible to promote better metal flow and
prevent trapping of the metal. In addition this is found to reduce
the incidence of cracking of the formed workpiece during subsequent
heat treatment. The flanges should then desirably lead from these
rounded corners at a tangent.
Rolling machines for forming a profile in the outer facing surface
of a workpiece, e.g., for forming an inner bearing ring, generally
comprises two heads, each of which carries a driven forming roll or
die. Between the two heads is mounted a rotatable mandrel over
which the workpiece or blank to be formed fits. A workpiece is
formed by rotating the rolls and squeezing the workpiece between
the forming rolls by relative movement of the heads towards one
another.
During rolling it sometimes happens that the workpiece being formed
will fracture. This generally occurs when the cross-section of the
workpiece is small compared with the size of the form being
produced in it, and hence the workpiece is less rigid. The reason
for the fracture is belived to be metal fatigue due to distortion
of the workpiece from the circular during rolling. As the workpiece
is rotating during the squeezing operation there is a tendency for
the circumference of the workpiece to grow and because the
diameteral dimension, measured in line with squeezing force, cannot
increase, the diameteral dimension measured at 90.degree. to the
force line will increase causing ovality in the workpiece. This,
therefore, causes the workpiece to change diameteral dimension
between these two limits, the number of reversals being dependent
on the speed of rotation and the ` in` feed rate of the forming
rolls. This causes the ring section to be alternately in
compression and tension which can rapidly cause a fatigue
fracture.
Therefore with this problem in mind, according to another aspect of
the invention there is provided a machine for rolling a workpiece
to a desired shape comprising a rotatable mandrel over which the
workpiece is to fit so as to be supported by the mandrel during
rolling, at least two heads evenly angularly spaced around the
periphery of the workpiece, each head being capable of carrying a
driven forming roll shaped to roll the workpiece to the desired
shape and being constrained so that the rolls are movable relative
to the workpiece in a direction radially of the workpiece so that
the workpiece is shaped by being squeezed by the forming rolls,
location means for initially locating the workpiece along its axis
relative to the forming walls, and a number of rotatably supported
growth control rolls which are spaced around the workpiece and are
arranged to remain in contact with the workpiece during rolling in
peripheral regions between the forming rolls and are arranged to be
prevented from retracting during rolling so avoiding substantial
deformation of the workpiece from the circular and preventing undue
metal fatigue.
These growth control rolls contact the workpiece and urge it
towards the mandrel in the peripheral regions between the forming
rolls so as substantially to prevent deformation of the workpiece
be becoming oval or other than substantially circular. The growth
control rolls must exert a force on the workpiece during which
reduces this deformation but at the same time does not
significantly form the cross-sectional profile of the workpiece.
Instead they should merely follow the forming of the workpiece and
restrain it to prevent the metal fatigue described above.
The growth control rolls must be urged against the workpiece by
means which prevent their retraction during rolling. They can be
advanced, for example, by a screw feed by and preferably urged
against the workpiece by hydraulic rams which prevent the growth
control rolls from retracting during the rolling process but enable
them to maintain contact against the workpiece as the form is
produced. We find that the force which the growth control rolls
exert on the workpiece should increase during forming up to a
maximum. For example, when rolling workpieces up to about 4 inches
outside diameter in the material known as EN 31, the maximum force
exerted on the workpiece should be about 12,000 lb.
It is preferred that these growth control rolls have a profile
which is the same or similar to that on the forming rolls so as to
interfer with the forming operation. Preferably the growth control
rolls have a profile identical with the forming rolls except that
they have no side flanges. In some cases, however, plain
cylindrical growth control rolls may be used.
Preferably, the growth control rolls are arranged in opposed pairs
or pairs of groups so as not to place any undue stress on the
support mandrel. The number of growth control rolls used can vary
depending on the size of the workpiece and the number of forming
rolls used. In the case where a pair of diametrically opposed heads
carry the forming rolls are used, a pair of diametrically opposed
growth control rolls can be used which are spaced at 90.degree. to
the forming rolls.
According to another aspect of the invention there is provided a
process for rolling a workpiece to a desired shape using a machine
as defined above in which a process for rolling a workpiece to a
desired shape using a machine as claimed in any of claims 8 to 13
in which the workpiece is initially located along its axis by the
location means, is then squeezed by the forming rolls sufficiently
to indent the workpiece to start the shaping of the workpiece and
form a location for the growth control rolls and thereafter the
workpiece is contacted by the growth control rolls, the growth
control rolls contacting the workpiece with a force sufficient to
prevent deformation from the circular between the forming rolls but
insufficient to cause substantial forming of the workpiece and,
after the workpiece has been rolled to the desired shape, the
forming rolls and the growth control rolls all start retracting at
the same time.
By following such a process the growth control rolls are able to
follow the shaping produced by the forming rolls while not
themselves significantly forming of the workpiece. The initial
contact of the forming rolls produces some work hardening and so
the growth control rolls do not distort or deleteriously affect the
shaping of the workpiece. In practice the growth control rolls can
contact the workpiece 26 almost immediately after the workpiece has
been contacted by the forming rolls.
In order to ensure that the growth control rolls follow shaping
produced by the forming rolls, the growth control rolls should be
mounted so as to be resiliently movable in a direction along their
rotational axes.
Once the forming rolls reach their full forming depth, it is
preferred that they remain there for the minimum number of
revolutions of the workpiece because longer dwell in that position
is found to increase the workpiece diametrical growth and
distortion which can cause excessive heating and fracture of the
workpiece.
At the ends of the rolling operation both sets of rolls start to
retract at the same time. In the case where all of the rolls are
urged against the workpiece by hydraulic rams, the timing of this
retraction can be initiated by a build-up in pressure in the rams
controlling the advancement of the heads. Alternatively, this
retraction can be initiated by say, a micro-swith controlled by a
timer or by the position of the heads.
The rate at which the forming rolls advance relative the workpiece
should preferably be from 0.010 to 0.020 inch per revolution of the
workpiece for workpieces of up to about 4 inches outside
diameter.
Normally the machine will have two heads which are positioned
opposite one another, the heads preferably being constrained to
move towards and away from one another along a path which coincides
with a diameter of a workpiece to be rolled so that the forming
rolls contact the workpiece during rolling at diametrically opposed
portions. In some cases, however, it may be desirable to provide
more than two heads, e.g., three heads spaced at 120.degree. to one
another around the periphery of the workpiece to be rolled.
The heads are all preferably urged in towards the workpiece during
the rolling operation by means of hydraulic rams. A similar ram can
be fixed to each head and then by linking all of the rams in
parallel to a source of pressurized hydraulic fluid, all of the
heads will move equally and so exert balanced forming pressures on
the workpiece and mandrel.
In order to ensure that the heads advance equally during a forming
operation they can additionally be linked mechanically. An
important advantage of linking the heads mechanically, is that the
piston seals of the hydraulic rams can be cheaper and simpler since
the mechanical link will constrain the head movements even though
there may be slight leakage past these seals. This also avoids
frequent replacement of these seals.
The machines of the invention are especially suitable for the
production of relatively small articles, i.e., articles having a
maximum outside diameter of 3 to 6 inches. In particular, the
machines are useful for the production of the inner bearing rings.
The invention is not, however, exclusively limited to the
production of these and, depending upon the shapes of the forming
rolls, gear wheels can, for example, be formed using toothed
rolls.
During rolling the forming rolls are rotated. This can suitably be
effected by hydraulic motors, one driving each forming roll. This
has the advantage that one can rapidly and easily reverse the
direction of rotation of the rolls during rollings as is sometimes
desirable to give a better rolling surface finish.
In the rolling of an inner bearing ring, one or more annular
grooves or recesses are formed in the outer facing surface of an
initially cylindrical workpiece. The inner facing of the workpiece
does not have to be altered and so the mandrel has a plain
cylindrical surface. This plain surface may be formed as part of
the mandrel itself or may be a separate cylindrical roll rigidly
fixed around a part of the length of the mandrel.
The diameter of the forming roll is dependent on the size of the
workpiece but in general one should use a roll having the largest
diameter which is practical in any instance. Having chosen the
diameter of the forming rolls the diameter of the growth control
rolls should then be chosen and be as large as possible.
The rolling of the workpiece can be effected without external
heating in which case the rolling is termed cold rolling, or
equally the rolling can be effected by preheating or externally
heating the workpiece during rolling in which case the rolling is
termed hot rolling.
BRIEF DESCRIPTION OF THE DRAWINGS
Cold rolling machines according to the invention will now be
described, by way of example, with reference to the accompanying
diagrammatic drawings, in which:
FIG. 1 is a plan view of a cold rolling machine for rolling a
profile into the outer facing surface of a cylindrical
workpiece;
FIG. 2 is an elevation of the machine shown in FIG. 1 showing
additionally a hydraulic circuit used in the operation of the
machine;
FIG. 3 is a cross-section taken on the line 3--3 of FIG. 2;
FIG. 4 is an enlarged diagram showing the forming rolls of the
machine shown in FIG. 1 and a formed workpiece;
FIGS. 5 and 6 are charts of the deviations of diameter of a typical
rolled workpiece prepared on the machine shown in FIG. 1 before and
after heat treatment, respectively;
FIG. 7 is an axial section through a workpiece before forming
according to the invention;
FIG. 8 is a section similar to FIG. 7 of the workpiece after
forming according to the invention; and
FIG. 9 is a sectional elevation detail of a cold rolling machine
for rolling a profile onto the inner facing surface of a
cylindrical workpiece .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The cold rolling machine 10 shown in FIGS. 1 and 2 comprises a
rotatably supported mandrel 12 and a pair of rotatable forming
rolls 14. The mandrel 12 is supported at either end in bearings 16
held by a stationary holder 18, while the rolls 14 are rotatably
mounted in bearings 20 in the arms 22 of yokes 24. These yokes are
slidably mounted on a base 26 so as to be movable towards and away
from one another. The holder 18 is fixed to the base 26.
As best shown in FIG. 4, the rolls 14 have annular humps 30 on
either side of which are flat rolling portions 32. They, therefore,
form a workpiece 34 into the shape of an inner bearing ring of a
ball bearing. The edges of the rolls 14 have projecting flanks 60
whose function will be described in due course.
The mandrel 12 fits within the workpiece 34 and maintains a plain
cylindrical inner facing surface on the workpiece during rolling.
The relative sizes of the workpiece 34 and the mandrel 12 are such
that the workpiece can freely slip onto the mandrel but, as soon as
the rolls 14 squeeze the workpiece between themselves and the
mandrel, the workpiece is squeezed against the mandrel which then
rotates with the workpiece during the rolling operation.
The yokes 24 are slidably mounted on the base 26 so that they can
both move towards and away from one another so as to effect the
rolling of the workpiece 34. The yokes are caused to slide in this
way by means of a pair of similar hydraulic rams 40. The two rams
are hydraulically connected in parallel as will be described. In
this way the two rolls 14 advance equally during rolling and do not
put undue strain on the mandrel 12 and its bearings 16.
As noted above the rolls 14 must be advanced exactly together and
this can be achieved to large extent by making the two rams 40
identical and then linking them hydraulically together in parallel
so that hydraulic fluid supplied via the line 124 to advance the
heads passes equally to each ram through branched lines 124a and
124b. Equally when the heads are to be withdrawn after a rolling
operation, hydraulic fluid is supplied through the line 126 and
this passes to each ram through branch lines 126a and 126b.
A suitable hydraulic circuit by which the rams 40 can be operated
is shown as part of FIG. 2. Pressurized hydraulic fluid is supplied
by a pump 150 to a supply line 152. Attached to this line are a
pressure gauge 154 and a pressure safety valve 155. A branch line
156 leads from the line 152 to a control valve 158. This 158
controls the supply and return of fluid to the lines 124 and 126
which supply the rams 40 in parallel through the branch lines 124a
and 124b and 126a and 126b so that both the rams move together.
Included in the line 124 between the control valve 158 and the rams
40 is a flow control valve 164 to control the rate at which the
rams can advance the rolls 14 during forming of the bank and having
a return by-pass with a check valve 165 whose function will be
described in due course, and a control valve 166 which is
de-energised by a limit switch 183 to change the piston advance
speed from fast to slow.
With the valve 166 energised, the flow control valve 164 is
by-passed and by operating control valve 158 the two rams 40 can be
caused to advance at a fast approach speed. At a pre-set advance
position the head contacts and trips the limit switch 183 which in
turn de-energises the control valve 166 and causes the hydraulic
fluid to pass through control valve 164 thereby causing the rams to
advance slowly. The rolls 14 contact the blank at this slow speed
and continue at this slow speed until full rolling depth is
reached.
The retraction of rolls 14 is achieved by reversing the action of
control valve 158. By this action, fluid is caused to flow through
the line 126 and the branch lines 126a and 126b to the front of the
rams 40, and fluid from behind the rams 40 to a reservoir 61
through the check valve 165 or through a control valve 166 which is
energised at the same time as the control valve 158.
In order to ensure that equal and identical advancement of the two
rolls 14 occurs, the two yokes can be mechanically linked together
in a suitable way.
The advantage of this mechanical linkage is that the piston seals
of the hydraulic rams can be cheaper and simpler and even slight
leakage past these seals can be accommodated.
The two forming rolls 14 are rotated at the same rate by hydraulic
motors being carried by the yokes 24. The advantage of driving the
rolls 14 by hydraulic motors is that their reduction of rotation
can be rapidly and simply reversed and this sometimes gives an
improved finish to the rolled surface.
As shown in FIG. 3, annular collars 42 are provided which are
mounted on the mandrel on either side of the workpiece and so
rotate with the mandrel and workpiece. The collars 42 are urged
against the sides of the workpiece by means of bellville springs 44
compressed between the collars and annular washers 46 which in turn
bear on annular ridges 48 formed on the mandrel. These collars 42
do not prevent widthwise spreading of the workpiece but do ensure
that the workpiece is accurately initially centred in relation to
the annular humps 30 on the rolls 14 before rolling starts and the
workpiece is contacted by the rolls 14. The force applied by the
bellville springs 44 can alternatively be supplied by hydraulic or
pneumatic rams operating directly on the annular collars 42.
In order to reduce substantially an ovality of the workpiece
occurring during rolling, a pair of opposed growth control rolls 50
are provided. These are rotatably supported by bearings 55 which
are carried in yokes 51 which are in turn attached to the piston
rods 52 of hydraulic cylinders 53. The rolls 50 have annular humps
54 of the same or similar shape to the humps 30 on the rolls 14. If
desired, however, the growth control rolls 50 can be plain
cylinders.
The hydraulic cylinders 53 are connected in hydraulic parallel to a
hydraulic power unit 151 via a change-over valve 58. During rolling
pressured hydraulic fluid is supplied through lines 56 to the
cylinders 53. This allows the pistons of the cylinders 53 to
advance as the form is produced in the workpiece and prevents their
retraction, thereby keeping the rolls 50 in contact with the
workpiece 34 with sufficient force to prevent the workpiece from
distorting to any large extent. This reduces metal fatigue and the
subsequent possibility of fatigue of the workpiece during
rolling.
They do not have any significant forming effect on the
cross-sectional profile of the workpiece and instead merely follow
the progress of forming by the rolls 14 and keep the workpiece in
contact with the mandrel so reducing the oval-shaped distortion
noted above. An additional flow control valve 200 is fitted in the
return line 57 from cylinders 53 to ensure controlled approach of
the growth control rolls to the workpiece.
On completion of rolling, the valve 58 is operated causing
pressurised hydraulic fluid to be supplied to the cylinders 53 via
lines 57 and a check valve 201. Out-going hydraulic fluid from the
cylinders returns to the reservoir 61 through the lines 56 and 59.
This causes the growth control rolls 50 to be retracted from the
workpiece.
To form an initially cylindrical workpiece this is first fitted on
the mandrel 12. The arrangement is such that the inner hollow
diameter of the workpiece is very slightly larger than the outer
diameter of the mandrel. Therefore the workpiece can easily slide
onto the mandrel.
Next the mandrel carrying the workpiece is reassembled in the
machine and the forming rolls 14 are rotated. Additionally, the
mandrel 12 and workpiece may be rotated by means (not shown) such
as, an air or electric motor so that substantial slipping does not
occur when the workpiece is contacted by the rolls 14. They are
then forwarded towards one another by the hydraulic rams 40 and
squeeze the workpiece and mandrel between themselves. The clearance
between the inner hollow diameter of the workpiece and the mandrel
is very small and as soon as the rolls 14 squeeze the workpiece
they cause it to grip the mandrel and so both the workpiece and
mandrel rotate together. Because there is no rolling between the
mandrel and workpiece, the inner hollow surface of the workpiece is
not formed or altered in shape.
The rate of rotation of the workpiece is governed by the roll
speed, and the relative diameters of the components and rolls. In
some cases a rate of rotation of the workpiece during rolling is
500 rpm.
During the rolling the annular humps 30 on the rolls 14 impress in
the workpiece a corresponding annular groove.
Immediately after the forming rolls 14 have contacted the workpiece
and made an initial impression and work hardening of the surface,
the growth control rolls 50 are advanced to contact the workpiece
and substantially reduce the extent of ovality which occurs. The
rolls 50 shown in the drawings have annular humps which correspond
to those on the rolls 14. The annular humps on the rolls 50 should,
therefore, fit in the groove formed by the rolls 14. To assist
this, it is preferred that the rolls 50 have some degree of freedom
to move in the direction along their axes so that they can readily
follow the forming operation without themselves shaping the
workpiece.
The advancement of the rolls 14 continues at a rate of, for
example, 0.010 to 0.020 inch per revolution of the workpiece until
the rolls 14 reach their full advanced position. Once they reach
the full rolling depth they, and the rolls 50, are maintained there
for a time usually termed the "dwell time" for up to two
revolutions of the workpiece and then all four rolls are withdrawn,
all starting simultaneously. It is important to ensure that the
workpiece makes the minimum number of revolutions at full rolling
depth otherwise heating and fracture of the workpiece can occur.
For example, the workpiece should not make more than about two
revolutions after the rolls 14 reach full rolling depths.
After the rolling has been completed and the rolls 14 and 50 have
retracted, the mandrel and workpiece are removed from the machine,
and the workpiece removed from the mandrel. Then the operation can
be repeated with a fresh cylindrical workpiece. The removal of the
formed workpiece and introduction of a fresh workpiece is
desirously effected automatically in any convenient way as will the
other operations of the machine.
As will be appreciated the machine according to the invention
described above is very effective in producing rolled parts and can
do this with accuracy, consistency and speed. In addition, the
provision of the rolls 50 ensures that metal fatigue and fracturing
of the workpiece will not occur during forming.
In order to shape and form the side edges of the workpiece the
rolls 14 have the projection flanks 60 which shape the side edges
of the workpiece.
As seen in FIG. 4 the flanks 60 are not at right angles to the axis
61 of rotation of the roll. Instead they are inclined at an angle
.alpha. of up to 15.degree. to the normal to the axis 63. This is
found to prevent scuffing and slivering of the side edges of the
workpiece which might break off and roll back into the rolled
surface so damaging it. Additionally, this inclination is found to
give better metal flow.
Also as shown in FIG. 4, as the metal flows during rolling to fill
the profile of the rolls, the metal reaches the corners 70 and then
flows up the side flanks 60. Because these flanks are only inclined
at a small angle relative to the normal to the rotational axis 61
of the roll, any variation in the amount of metal flow, i.e., in
the distance x will produce only an extremely small variation in
the dimension y. Therefore provided the initial shape and size of
the workpiece is accurately maintained, it is possible to produce
rolled and shaped workpieces having a plane containing points Z
which is always accurately spaced from the centre line W--W of the
shaped workpiece, i.e., the profile given to the workpiece is
always accurately located in relation to the plane containing the
point Z. The workpiece should initially be centred before rolling
and this is achieved by the collars 42 as described above. This, of
course, is an important advantage when further operations, e.g.,
grinding, are to be effected on the rolled workpiece because then
one has a conveniently and accurately positioned reference plane at
the edge of the rolled workpiece.
Generally the initial workpiece has a small inside and outside
diameter and narrower width than the finished shaped workpiece. The
volume of the workpiece remains constant, however. The final
dimensional tolerances of the shaped workpiece are largely
dependent upon the size of the initial blank workpiece.
Also it is possible to form bore chambers 74 (FIG. 4) on the
workpiece before or after rolling.
As best seen in FIG. 4 there are no sharp corners on the rolls 14,
e.g., at the corners 70 and 72. All these corners have the maximum
radius possible and the side flanks 60 lead from the corner radii
with the portions 32 at a tangent. In this way, it is possible for
the metal to flow easily in the direction of the arrows 101 so
reducing strains in the formed workpiece. This also is found to
reduce any tendency of shaped workpieces to crack during a
subsequent heat treatment.
The track roundness of a typical rolled inner bearing ring of about
13/4 inches bore diameter prepared on the machine described above
before and after heat treatment is shown in FIGS. 5 and 6,
respectively, the graphs of FIGS. 5 and 6 being measured at the
minimum diameter of the annular groove in the workpiece. Each
radial division on the graph representing 0.0025 inch. As can be
the out of round both before and after heat treatment is relatively
small and little distortion occurs during first treatment showing
that the ring has excellent grain flow structure and evenly
disposed loop stresses. In addition, the small degree of out of
round and the low distortion which occurs during heat treatment,
reduces the amount of any final grinding required to finish the
shaped workpiece to its final dimensions.
When forming inner bearing rings as described above in connection
with the drawings, a material having a surface hardness of 25 to 32
Rc gives best results, although softer materials can be used.
FIGS. 7 and 8 show respectively the dimensions of a typical
cylindrical workpiece before and after rolling according to the
invention to the shape of an inner bearing ring. The workpiece was
made of the material defined by the British Standards Institution
as EN31 and it had a surface hardness of 27 Rc. The nominal
diameter of the forming rolls 14 used as 10 inches and the "in
feed" rate of these rolls during forming was 0.01 inch/revolution
of the workpiece. The rate of revolution of the rolls 14 during
forming was 62 r.p.m. The maximum rolling force applied by the
rolls was 40,000 lb, and the dwell time was 0.75 second.
The various dimensions A to I on FIGS. 7 and 8 were in inches as
follows:
A--1.5644
b--1.138
c--0.584
d--1.6082
e--1.1712
f--0.648
g--0.6397
h--0.6397
i--1.4523
the cold rolling machine 80 shown in FIG. 9 is for providing a
profile on the inner facing surface of a cylindrical workpiece 82
so forming, for example, an outer bearing ring. The workpiece is
rolled between a profiled inner roll 84 which is rotatably carried
by means (not shown) and an outer cylindrical roll 86 also
rotatably carried by means (not shown).
The inner roll 84 has an annular hump 88 on either side of which
are plain cylindrical portions 89 on either side of which are in
turn flanks 90. It therefore has a profile similar to that of the
rolls 14 described above, the equivalent parts of the roll 84
serving similar functions.
Therefore, provided the workpiece is initially centred in relation
to the hump 88, workpieces are accurately formed with a side edge
which can be used to locate the rolled workpiece accurately for
further operations.
The workpiece is initially centred by means of a resiliently
mounted collar 92 and cup-shaped hood 94. The collar 92 fits within
the roll 86 and has an annular flange 96 which is fixed to the roll
86 by screws 98. Between the heads of the screws 98 and the flange
96 are spring washers 100. It is, therefore, possible to move the
collar 92 in the direction of the arrow 102 so compressing the
washers 100. The cup-shaped hood 94 also fits within the roll 84
and is mounted on a rotatable thrust bearing (not shown) mounted in
its turn on the end of a rod 104 connected to a pneumatic
cylinder.
The workpiece 82 is mounted in the roll 86 by first sliding it into
place against the collar 92, the workpiece having a slightly
smaller outer diameter than the internal diameter of the roll 86,
then it is pressed towards the left as shown in FIG. 9 by the hood,
a predetermined pressure being applied in the pneumatic cylinder to
compress the spring washers 100 sufficiently to bring the workpiece
to the accurately desired location. Because the washers 100 and
pneumatic cylinders have some resiliency they do not inhibit
width-wise spread during rolling.
The roll 84 is rotated, say, at 500 r.p.m., although, the exact
rate depends as noted above upon the roll speed and the relative
diameter of the various components, and the cylindrical roll 84 is
also pre-rotated so that when the workpiece is contacted by the
roll 84 there is substantially no slipping.
Next the rolls 84 and 86 are moved in the direction of the arrow
106 relative to one another to squeeze and form the workpiece.
During rolling the workpiece expands slightly in diameter to fit
within the roll 86. This ensures an accurately final outside
diameter.
It will be noted that the inner bore of the roll 86 flares slightly
towards the right as seen in FIG. 9. This makes it easier to insert
and withdraw the workpiece.
A latitude of modification, change and substitution is intended in
the foregoing disclosure and in some instances some features of the
invention will be employed without a corresponding use of other
features. Accordingly it is appropriate that the appended claims be
construed broadly and in a manner consistant with the spirit and
scope of the invention herein.
* * * * *