Apparatus for spin-forming a circular body from a flat blank metal workpiece

Abstract

A machine for spin-forming a solid disk blank having a center axial bore into a pulley configuration exhibiting an outer peripheral pulley groove and a flanged bore bearing retainer. Die members maintain the disk blank on the machine axes by clamping the disk blank between an upper and lower die members. A power source affects rotational motion of at least one of the die members to affect rotation of the disk blank. A splitting tool, a swaging tool, and a splitting-swaging tool are moveable for engaging the disk blank and affecting splitting and swaging of the bore and peripheral edge. A rotatable inner tool spindle comprises the splitting-swaging tool connected thereto and is movable horizontally such that the tool splits and swages the center axial bore. A power source affects rotational motion of the spindle and thus the rotational motion of the splitting-swaging tool.

1 . An apparatus having primary Ay vertical and Bx horizontal axes to spinform a flat disk blank having a center axial bore into a pulley configuration exhibiting an outer peripheral pulley groove and bore flanges to contain a bearing, the machine comprising:
 a first spindle rotatable about the Ay axis;   at least one die member operable to engage the disk blank and the first spindle causing the disk blank to rotate with the first spindle;   a first motor coupled with the first spindle that is operable to cause the first spindle to rotate;   a second spindle rotatable about the Ay axis and movable about the Bx horizontal axis causing the second spindle to rotate about an axis that is parallel to the Ay axis;   a second motor coupled with the second spindle that is operable to cause the second spindle to rotate;   a splitting-swaging tool coupled with the second spindle that rotates with the second spindle; and   a controller coupled with the first motor and the second motor and operable to control the rotational speed of the first motor and second motor;   wherein the controller is operable to control the first motor and the second motor to cause the splitting-swaging tool and the disk blank to rotate about the Ay axis in the same direction.   
     
     
         2 . The apparatus set forth in  claim 1 , wherein the controller is operable to cause the first and second motors to rotate at rotational speeds which causes rotational speed of the splitting-swaging tool to match the rotational speed of the disk blank. 
     
     
         3 . The apparatus set forth in  claim 1 , wherein the controller is operable to cause the first and second motors to rotate at rotational speeds that cause the rotational speeds of the splitting-swaging tool and the disk blank to be within 5% of each other. 
     
     
         4 . The apparatus set forth in  claim 1 , wherein the controller is operable to cause the first and second motors to rotate at rotational speeds that cause the rotational speeds of the splitting-swaging tool and the disk blank to be within 2% of each other. 
     
     
         5 . The apparatus set forth in  claim 1 , further comprising a splitting tool rotatably powered and movable on the Bx horizontal axis to engage the outer peripheral edge and affect spitting of the edge. 
     
     
         6 . The apparatus set forth in  claim 1 , further comprising a swaging tool rotatably powered and movable on the Bx horizontal axis to engage the outer peripheral edge and affect swaging of the edge into a pulley groove configuration. 
     
     
         7 . The apparatus set forth in  claim 1 , further comprising a lateral motion inducing mechanism for moving the second spindle horizontally causing the splitting-swaging tool to engage the center axial bore of the disk blank. 
     
     
         8 . The machine as claimed in  claim 7 , wherein the lateral motion inducing mechanism for moving the second spindle horizontally is a hydraulic cylinder, wherein the piston of the hydraulic cylinder is operatively coupled with the second spindle and affects horizontal movement of the second spindle and splitting-swaging tool. 
     
     
         9 . The machine as claimed in  claim 7 , wherein the lateral motion inducing mechanism for moving the second spindle horizontally is a pneumatic cylinder, wherein the piston of the pneumatic cylinder is operatively coupled with the second spindle and affects horizontal movement of the second spindle and the splitting-swaging tool. 
     
     
         10 . The apparatus set forth in  claim 1 , further comprising a spur-ring gear combination coupling the first motor to the first spindle. 
     
     
         11 . The apparatus set forth in  claim 1 , the at least one die member comprises an upper die member and a lower die member, wherein the disk blank is mounted between the upper die member and the lower die member. 
     
     
         12 . The apparatus set forth in  claim 11 , wherein the upper die member has a bore allowing the splitting-swaging tool to pass therethrough to engage the disk blank. 
     
     
         13 . The apparatus set forth in  claim 12 , wherein the upper die member is conical in shape. 
     
     
         14 . The apparatus set forth in  claim 12 , further comprising a lifting mechanism that the height of the second spindle along the Ay axis. 
     
     
         15 . The apparatus set forth in  claim 14 , wherein the lifting mechanism comprises a hydraulically operated piston that is controlled by the controller.