JP2019528179A - Flow molding machine and molding method for manufacturing wheels - Google Patents

Abstract

The present invention relates to a flow molding machine and a molding method for manufacturing a wheel (50) with a rim (60) from a workpiece (5), the spinning being designed to form the rim (60). A mandrel (20) and a counter mandrel (12), wherein the workpiece (5) is pressed against the spinning mandrel (20) or the counter mandrel (12) and clamped And at least one compression roller (40) that can be advanced toward the workpiece (5) to form a rim (60). According to the invention, the spinning mandrel (20) has a sleeve-like peripheral element (30) that can move axially during the forming process, and the spinning mandrel (20) ) Has a support (22) mounted so as to be movable in the axial direction. A front element (24) is arranged at the free end of the support (22) and a radial hub (52) or deep bottom (64) is countered with the front element (24) of the spinning mandrel (20). -It can be clamped axially between the mandrel (12). By using the control device, while forming the rim (60), at least one compression roller (40) and the surrounding element (30) of the spinning mandrel (20) are axially oriented relative to the workpiece (5). Can be moved to.

Description

  The present invention is a flow molding machine for manufacturing a wheel, in particular a vehicle wheel having a rim, from a workpiece according to the preamble of claim 1, wherein the spinning mandrel is configured on the outside to form a rim, A counter mandrel capable of axial displacement with respect to a spinning mandrel, wherein the workpiece is clamped axially on the spinning mandrel and / or counter mandrel, and a spinning mandrel And a rotational drive for rotationally driving the counter mandrel with the clamped workpiece, and at least one compression roller that can be pushed axially and radially to the workpiece to form a rim; The present invention relates to a flow molding machine including

  The invention further relates to a forming method for manufacturing a wheel, in particular a vehicle wheel with a rim, from a workpiece according to the preamble of claim 7, the workpiece being configured on the outside so as to form a rim. The clamped workpiece is clamped on the spinning spinning mandrel and / or counter mandrel, and the clamped workpiece is placed in rotation by a rotary drive and at least one compression roller is pressed against the rotating workpiece and axially In addition, the present invention relates to a molding method in which a rim is formed by being advanced in a radial direction.

  Flow molding machines and methods of this type for producing wheels, in particular vehicle wheels, have been known for a long time. For example, a general method for manufacturing vehicle wheels from disc-shaped blanks can be obtained from DE19615675A1. The workpiece here is clamped on a spinning mandrel in a flow molding machine, the outer circumference of which is corresponding to the inner contour of the rim to be formed. By using at least one compression roller, the workpiece is molded tiplessly on the spinning mandrel to form a rim well and a lateral rim flange.

  In the vehicle wheel industry, it is often necessary to provide vehicle wheel models with rims of various widths. For example, many vehicles may require a larger wheel width on the driven rear axle than on the front axle. Furthermore, it is customary to mount vehicle wheels of various wheel widths on one model of vehicle from one manufacturer depending on the engine output.

  In order to produce vehicle wheels with different rim widths, it is necessary to provide different spinning mandrels. This can be very costly and requires multiple flow molding machines with various spinning mandrels, or the flow molding machine can be replaced by replacing the spinning mandrels Means. However, this procedure is time consuming and therefore costly.

  From WO 2005/065049 A2 a method for manufacturing vehicle wheels with a deep rim is known. The deep rim has a radial indentation in the central region. To flow mold this type of deep rim, a multi-part spinning mandrel is disclosed that needs to be disassembled after the forming step.

  JP 60-158933 discloses an apparatus for flow forming comprising an external forming roller and a two-part internal forming roller. The internal forming roller here has a static external contour that matches the internal contour of the workpiece.

  Japanese Laid-Open Patent Publication No. 58-202927 discloses an apparatus for forming a cylindrical workpiece by advancing an external forming roller, wherein the cylindrical preform is formed by an internal tool by means of first and second tool halves. Fixed on top.

  CN10194326 discloses an apparatus for forming a cylindrical hollow body by using an external forming rotor and a two-part internal forming tool. The internal contour of the cylindrical workpiece that can be created here corresponds to the external contour of the internal tool. The internal tool is formed in two parts that can be removed from the cylinder on two opposite sides.

  From US 2003/145466 A1 a method for manufacturing wheel rims can be obtained, in which a hollow cylindrical body is provided between two internal forming tools that can be advanced axially, A shape is introduced into the cylindrical preform by using a first external forming tool and a second contour is introduced onto the workpiece by using a second external forming roller. The internal contour of the workpiece here corresponds to the external contour of the internal tool.

  The present invention provides a flow molding machine and a molding method for manufacturing a wheel, whereby a wheel having various dimensions and shapes can be manufactured particularly efficiently. For the purpose.

  This object is achieved on the one hand by a flow molding machine having the features of claim 1 and on the other hand by a molding method having the features of claim 7. Preferred embodiments of the invention are specified in the respective dependent claims.

  The flow molding machine according to the invention comprises a spinning mandrel having a sleeve-like peripheral element that can be displaced axially during molding, and a control device is provided so that the rim is being molded. , Characterized in that at least one compression roller and the surrounding elements of the spinning mandrel can be moved axially relative to the workpiece.

  The basic concept of the present invention is to provide a variable spinning mandrel for wheel rim molding or flow molding, the spinning mandrel being adjusted or displaced during molding. By using such a variable adjustable spinning mandrel, various shapes and dimensions of the drum-like rim can be formed during wheel manufacture. The spinning mandrel here preferably has a disk-shaped front element and a sleeve-shaped peripheral element that can be adjusted axially during molding. In this way, the surrounding elements can be displaced, for example in the same axial direction, with the compression roller abutting from the outside, so that virtually any length of the rim can be formed. Therefore, when the rim dimensions change, a time-consuming and costly flow molding machine setup change is no longer necessary. Adjustment of the sleeve-like peripheral element and the at least one compression roller is effected by using an electronic control unit. The workpiece can be disk-shaped, in which case the radial hub is already preformed. Alternatively, the workpiece can be ring shaped, in which case the hub is attached after the rim has been formed.

  A preferred embodiment of the invention resides in the fact that the sleeve-like peripheral element is at least partly configured in a conical shape while tapering towards the free end. If the surrounding element has a conical shape, various inner diameters of the conical shape can be used to support the compression roller abutting from the outside from the inside. Therefore, the inner contour of the rim can be created in various shapes, and in this case, for example, an undercut region provided in a deep bottom rim can be easily formed. In this case, the conical surrounding element is displaced in both directions along the axis of rotation during molding. The outer contour of the surrounding element in this case is completely independent of the inner contour of the rim to be formed. Only the cone need only extend over the maximum and minimum diameters that occur within the inner contour of the rim.

  According to the development of the invention, it is advantageous that the forming area is arranged on the area of the surrounding element and is configured to form a rim flange on the rim. The molding area in this case has a curved contour, so that the inner area of the rim flange to be formed is predefined. In the case of wheels with rim wells of various lengths, the shape of the rim flange in the peripheral area of the rim often remains unchanged.

  In particular, to produce a deep rim according to an embodiment of the present invention, the controller may provide a relative axial displacement of at least one compression roller and surrounding elements to form an axial undercut region in the rim. At least one compacting roller is first located on the first diameter region of the conical surrounding element and then smaller than the first diameter region , Located on the second diameter region of the surrounding element, and then located on the third diameter region of the surrounding element that is larger than the second diameter region. As a result of the appropriate axial adjustment of the conical surrounding element, a smaller diameter area can be provided to correspond to the compression roller in order to form the central area of the deep rim. Due to the formation of the two side regions, the conical surrounding element is adjusted in each case so that the larger diameter region faces the radial direction of the compression roller, so that the axial direction of the deep rim The entire undercut area can be created on the central area of the rim.

  According to the development of the flow molding machine according to the invention, the spinning mandrel has a support on which the surrounding elements are slidably mounted in the axial direction, and on the free end side of the support there is a front element. Advantageously, the arranged and radial hub can be clamped axially between a spinning mandrel with a front element and a counter mandrel. This allows only a simple replacement of the sleeve-like surrounding elements when maintenance work is required or when the diameter or shape of the manufactured wheel changes.

  In principle, the axial sliding of the surrounding elements can be performed in any desired manner. It is particularly preferred, according to a variant of the embodiment of the invention, that at least one adjusting element, in particular an adjusting cylinder or spindle drive, is provided on the support for the axial sliding of the surrounding elements.

  Adjustment cylinders that can be operated hydraulically or pneumatically correspond to typical actuators on conventional flow molding machines. It is also possible to convert an ejector that may be present with an axial adjustment movement for sliding the surrounding elements. Alternatively, a spindle drive, i.e. a rotary drive, can be used, in which the rotational movement is converted into an axial movement by using a suitable spindle arrangement.

  In order to improve the variety of shapes, it is realized by the development of the invention that the front element is mounted on the support so that it can be exchanged. The front element may be provided to accommodate the counter mandrel for axial clamping action of the workpiece in the radially extending disc or hub region. Depending on the design of the hub area that is preformed, for example by casting or forging, the front element and counter mandrel are configured. However, if there is an appropriate change in shape, the front element can be a corresponding front plate on the counter mandrel, which can be easily released, e.g. by releasing a screw-in joint, to a new element Can be exchanged. In order to clamp ring-shaped and / or disk-shaped workpieces, the counter mandrel can be a chuck for radial clamping action.

  The method according to the invention comprises that the spinning mandrel has a sleeve-like peripheral element that is axially displaced while the rim is being formed, and at least one compression roller and spinning while the rim is being formed. -The surrounding elements of the mandrel are axially displaced relative to the workpiece in a coordinated manner. The process according to the invention can preferably be carried out on a flow molding machine according to the invention as described above. In particular, the advantages described above can be achieved in relation to shape flexibility and versatility.

  In particular, flow molding with high accuracy is achieved by uniformly distributing the plurality of compression rollers around the periphery of the workpiece with respect to the workpiece and shifting them relative to each other in the axial direction according to a modification of the embodiment of the present invention. Achieved by moving forward. Preferably three or four compression rollers are arranged around the periphery of the workpiece. In this way, the forming force can be distributed over a plurality of compression rollers, thereby allowing the forming to be carried out in a manner that is particularly safe for workpieces and machines.

  In the method according to the invention, the compression roller and the surrounding elements of the spinning mandrel are axially displaced relative to the front element or the clamped workpiece. The compression roller and the surrounding element in this case are preferably displaced differently, especially when the more complex inner contour of the rim area is shaped by using a conical surrounding element.

  In order to produce a wheel with a particularly deep bottom rim, at least one compression roller is initially placed on the first diameter area of the conical surrounding element in order to form an axial undercut area in the rim. Located, then on a second diameter region of the surrounding element that is smaller than the first diameter region, and then on a third diameter region of the surrounding element that is larger than the second diameter region Is advantageous due to a variant of the method of the invention. The third diameter region can have a diameter size like the first diameter region.

  The deep region on the rim here can be arranged and formed as desired over the axial length of the rim. The deep bottom region here can be configured not only in the central region but also on the side region of the rim on the opposite side of the radial hub region of the disc-shaped workpiece. In this way, a vehicle wheel is formed with a rim having a deep region that is positioned relatively far away in the outward direction, resulting in a vehicle wheel that looks particularly large. This type of vehicle wheel with an outer deep bottom region may be desirable for various wheel designs. The side surface of the deep region is formed under the action of the compression roller using the larger diameter region of the conical surrounding element and the base of the deep region using the smaller diameter region.

  According to another advantageous method variant of the invention, surrounding elements having an axial length smaller than the rim to be formed are used and wheels with different axial lengths of the rim are It is realized that it is formed by elements. Thus, for example, using substantially the same design of the disk-shaped hub region, various rim widths can be produced from the starting workpiece with less effort by the method according to the invention.

  In principle, the molding can be performed with a suitable horizontal axis of rotation. A particularly precise execution of the forming method according to the invention is achieved by a variant of the method by placing the workpiece in rotation about a vertical axis of rotation during forming. The advancement of the compression roller in this case is substantially performed in the radial horizontal direction.

  The present invention will be described in more detail below by reference to preferred exemplary embodiments, schematically illustrated in the accompanying drawings. This figure is shown as follows.

It is sectional drawing of the principal part of the flow molding machine by this invention. It is sectional drawing of the vehicle wheel manufactured by this invention. 3a-3c are cross-sectional views of a workpiece during various forming steps according to variations of the present invention. Figures 4a-4c are cross-sectional views of a workpiece at various forming steps according to another variation of the present invention. Figures 5a to 5d are cross-sectional views of a workpiece at various forming steps according to another variation of the present invention. Figures 6a-6e are cross-sectional views of a workpiece at various forming steps according to another variation of the present invention.

  A flow molding machine 10 according to the present invention has a spinning mandrel 20 and an opposing counter mandrel 12, between which a disk-shaped hub region 6 having a centering hole and a molding. The workpiece 5 with the surrounding area 7 is clamped in the axial direction. The counter mandrel 12 and the spinning mandrel 20 are rotatably mounted by using drive flanges 16 and 17, respectively, and are connected to a rotary drive (not shown), preferably each connected to a separate rotary drive, The spinning mandrel 20, counter mandrel 12, and clamped workpiece 5 can be rotationally driven about a vertical central rotational axis 2 during molding.

  The spinning mandrel 20 has a central support 22 on which a ring or disk-shaped front element 24 is removably attached by means of screws. Similar to the opposing counter mandrel 12 provided with the forming surface 14, the front element 24 is adapted to the shape of the workpiece 5 to be clamped. If there is a change in the design of the workpiece 5, in particular the hub area 6, the counter mandrel 12 and the front element 24 can be easily removed by using a screw connection and replaced with a suitably adapted new element. it can. On the molding surface 14, a first rim flange 56 of the vehicle wheel 50 to be manufactured can be formed.

  Further, the spinning mandrel 20 has a sleeve-like peripheral element 30 mounted on the support 22 so as to be slidable in the axial direction. For the purpose of sliding, the surrounding element 30 is attached to a sliding element 28, which by means of an adjustment cylinder (not shown), along the axis of rotation 2 and an upper starting position, 1 is slidable in the axial direction. The surrounding element 30 has an outer conical surface 32 that tapers upward on its front or upper region. Formed in the bottom end or central region is a molded region 34 that is designed to form a second rim flange 58 on the vehicle wheel 50.

  In order to form the vehicle wheel 50 from the workpiece 5, a plurality of compression rollers 40, schematically shown only one, are pressed against the peripheral area 7 of the workpiece 5 and advanced in the radial direction. In this case, the peripheral element 30 of the spinning mandrel 20 is in the upper initial position, thereby acting as a rotary bearing for the compression roller 40 abutting on the workpiece 5. The compression roller 40 is adjusted in the axial direction and to some extent in the radial direction to form a rim region. In this case, the wall thickness of the peripheral region 7 is reduced and leveled to form the rim region. By using the control device, as the compression roller 40 is moved, the desired inner diameter region always functions as a rotating bearing that receives the compression roller 40 at a desired position. The surrounding element 30 is displaced in the axial direction. Depending on the intended length of the rim region, the surrounding element 30 remains axially stationary, so that during further displacement of the compression roller 40, the material of the workpiece 5 is formed in the forming region 34, thus A second rim flange 58 is flow molded into the hub region 6 corresponding to the first rim flange 56.

  In FIG. 1, a total of three different lengths of vehicle wheels 50 are schematically shown in order to show the flexibility of the flow molding machine 10 according to the invention in wheel manufacture. The spinning mandrel 20 is therefore generally independent of the vehicle wheel 50 being formed and can be used for various axial lengths and internal contours. Only the electronic controller must be adapted for manufacturing, but no mechanical conversion work on the flow molding machine 10 is required.

  In FIG. 2, in a very schematic form, another shape of a vehicle wheel 50 that can be produced according to the invention is shown. The vehicle wheel 50 includes a disk-shaped hub 52 and a drum-shaped rim 60 that are arranged substantially rotationally symmetrically with respect to the wheel shaft 51. In the area of the hub 52, a central hole 54 and other holes can be provided depending on the design.

  The rim 60 is provided with a rim well 62 that extends from the first rim flange 56 to the second rim flange 58. A deep region 64 is formed in the central section of the rim well 62. The deep bottom region 64 represents a radial narrowing in the rim well 62, and thus an undercut portion 70, which is shown in a particularly clearly schematic form in FIG. The deep region 64 can also have different dimensions and different arrangements, in particular closer to the freely projecting second rim flange 58.

  The deep region 64 has two slightly inclined lateral sides 66 that extend substantially radially and extend to a generally cylindrical base 68. A vehicle wheel with a rim 60 and a deep region 64 can be produced by means of the method according to the invention using a peripheral element 30 that is suitably conically configured as a rotary bearing that receives an externally engaging compression roller 40. . The surrounding element 30 in this case is displaced axially by using a control device and a suitable adjusting element depending on the position of the compression roller 40, resulting in a suitable diameter area.

  According to a variant of the method of FIGS. 3a to 3c, a pot-shaped workpiece 5 with a radial hub region 6 and a drum-like peripheral region 7 was flow-formed according to FIG. 3b by the method of the invention. In the case of a wheel blank or formed into a finished wheel according to FIG. 3c, in the case of finishing according to FIG. 3c, FIG. 3b shows, for example, the wheel blank before turning.

  According to a variant of the method of FIGS. 4 a to 4 c, a workpiece 5 is used, which is Y-shaped in half section, on the radial hub area 6 and on both sides of the radial hub area 6. And a drum-like peripheral region 7 extending. In this manner, a flow molding machine can be used in which the counter mandrel is configured identically or generally identically to the spinning mandrel and has displaceable peripheral elements.

  In a variant of the method according to FIGS. 5a to 5d, a disc-shaped workpiece 5, also known as a circular blank, is used as the starting workpiece. This is formed into an intermediate shape according to FIG. 5b by turning and partially dividing. The radial hub region 6 and the V-shaped surrounding region 7 are formed at this stage. The workpiece 5 is then finally shaped into the vehicle wheel 50 with the deep bottom of FIG. 5d, via an intermediate step according to FIG. 5c.

  According to another method variant of FIGS. 6a to 6e, the tubular workpiece 5 forming the surrounding region 7 can be used as the starting workpiece. The workpiece 5 here can be clamped by means of a counter mandrel configured as a radial chuck, for example as a four jaw chuck. The spinning mandrel can be used to machine the entire radially inner side of the workpiece 5. According to FIG. 6e, the wheel 50 consisting only of the drum-shaped rim 60 is formed. If a hub area is desired, a separately shaped hub can be attached to the rim 60 by, for example, welding, particularly friction welding or screwing.

  According to another method variant, the tubular workpiece 5 according to FIG. 6a with areas spread on both sides can be held via a spinning mandrel according to the invention and is first deepened by pressing or profile processing. A bottom is created, whereby this area is used for axial transmission or retention for axial sliding or torque transmission for subsequent flow forming processes with axial sliding of sleeve-like surrounding elements Used for.

Claims (12)

A flow molding machine for producing a vehicle wheel (50) with wheels, in particular a rim (60), from a workpiece (5),
A spinning mandrel (20) configured on the outside to form the rim (60);
A counter mandrel (12) that is axially displaceable relative to the spinning mandrel, wherein the workpiece (5) is on the spinning mandrel (20) and / or the counter mandrel (12) A counter mandrel clamped to,
A rotary drive for rotating the spinning mandrel (20) and the counter mandrel (12) with the clamped workpiece (5);
A flow molding machine comprising at least one compression roller (40) that can be pressed against the workpiece (5) to advance axially and radially to form the rim (60);
The spinning mandrel (20) includes a sleeve-like peripheral element (30) that can be displaced in the axial direction during molding, and a support on which the peripheral element (30) is slidably mounted in the axial direction. The front element (24) is disposed on the free end side of the support (22), and the workpiece (5) has a radial hub (52) or a deep bottom (64). Can be clamped axially between the spinning mandrel (20) with the front element (24) and the counter mandrel (12),
A control device is provided, by which the peripheral element (30) of the at least one compression roller (40) and the spinning mandrel (20) is moved while the rim (60) is formed by the control device. A flow molding machine, characterized in that it can be displaced axially relative to the workpiece (5).   The flow molding machine according to claim 1, characterized in that the surrounding element (30) is at least partly configured in a conical shape and tapers towards the free end.   The region of the surrounding element (30), characterized in that a molding region (34) is arranged and configured to form a rim flange (58) on the rim (60). 2. The flow molding machine according to 2.   In order to form an axial depressing region (70) on the rim (60), the control device can provide a relative axial displacement of the at least one compression roller (40) and the surrounding element (30). Configured so that the at least one compression roller (40) is initially located on a first diameter region of the conical circumferential element (30) and then the first diameter Located on a second diameter region of the surrounding element (30) that is smaller than a region and then located on a third diameter region of the surrounding element (30) that is larger than the second diameter region. The flow molding machine according to claim 2 or 3, characterized by the above.   5. An adjustment element, in particular an adjustment cylinder or a spindle drive, is provided for axial sliding of the peripheral element (30) on the support (22). The flow molding machine described in 1.   6. A flow molding machine according to any one of claims 3 to 5, characterized in that the front element (24) is mounted on the support (22) so that it can be replaced. A molding method for manufacturing a vehicle wheel (50) with wheels, in particular a rim (60), from a workpiece (5),
The workpiece (5) is clamped on a spinning mandrel (20) and / or a counter mandrel (12) which are configured externally to form the rim (60);
The clamped workpiece (50) is rotated by a rotary drive;
In a molding method, at least one compression roller (40) is pressed against said rotating workpiece (5) and advanced axially and radially to form said rim (60),
The spinning mandrel (20) includes a sleeve-like peripheral element (30) that is axially displaced while the rim (60) is formed, and the peripheral element (30) is slid in the axial direction. A support (22),
A front element (24) is arranged on the free end side of the support (22), and a radial hub (52) or deep floor (64) of the workpiece (5) is connected to the front element ( 24) clamped axially between the spinning mandrel (20) and the counter mandrel (12) with
While the rim (60) is being formed, the at least one compression roller (40) and the peripheral element (30) of the spinning mandrel (20) are axial with respect to the workpiece (5). A forming method characterized by being displaced.   The plurality of compression rollers (40) are pressed against the workpiece (5), are uniformly distributed around the periphery of the workpiece (5), and are moved forward relative to each other in the axial direction. The molding method according to claim 7, wherein the molding method is characterized.   9 or 8, characterized in that, while the rim (60) is being formed, the at least one compression roller (40) and the surrounding element (30) are displaced differently in the axial direction. The forming method as described.   In order to form an axial depressing region (70) on the rim (60), the at least one compression roller (40) is first of all a first diameter region of the conical surrounding element (30). Located above, then the at least one compression roller (40) is located on a second diameter area of the surrounding element (30) that is smaller than the first diameter area, and then the at least one 10. The compression roller (40) according to any one of claims 7 to 9, characterized in that it is located on a third diameter area of the surrounding element (30) that is larger than the second diameter area. The forming method as described. A peripheral element (30) having an axial length smaller than the rim (60) to be formed is used,
11. Molding according to any one of claims 7 to 10, characterized in that the peripheral element (30) is used to form a wheel with the rim (60) of various axial lengths. Method. 12. A molding method according to any one of claims 7 to 11, characterized in that the workpiece (5) rotates around a vertical axis of rotation (2) during molding.

Images