Method of manufacturing drive plate

Abstract: A method of manufacturing a driver plate comprises the steps of swaging the outer peripheral portion of a disk-shaped raw material (1) in the radial direction thereof using a swaging die (5,6) so as to form the outer peripheral portion (1a) in a thick wall portion, holding the swaged material between an upper and a lower die (8,7) and pressing the material through the upper and lower dies so as to form it into a dish-shaped blank, and pressing radially the thick-walled outer peripheral portion (1a) of the dish-shaped blank held between a support die (12) disposed either on the outside or on the inside thereof and a gear tooth profile forming die (11) so as to form gear teeth either on the radially outside or on the radially inside of the outer peripheral portion. As an alternative, gear teeth may be formed by cold rolling work or gear teeth cutting work using a gear hobbing machine or one of other gear teeth cutting machines.

Description: The invention relates to a method of manufacturing drive plates according to the preamble of claim 1. Drive plates of this kind are to be used in drive gears of clutches for motor vehicles. The GB-A 2 045 665, which shows the features of the precharacterising portion of the independent claim, discloses a method for forming a combination of a flex-plate and gear members. The method includes the steps of heating the outer periphery of a disc during rotation to a temperature of for example 704 to 760°C and for deforming the outer periphery of the disc radially inwardly to form a flanged outer periphery which extends axially outwardly from both sides of the disk, forming a T-shaped cross section. Heating reduces the forces necessary for rolling the flanged portion. Large sized drive plates each of which diameter is 200 mm or more have been manufactured by the steps of press-fitting a dish-shaped member formed by pressing a disc-shaped thin plate material into an annular gear member having gear teeth formed along the outer periphery of an annular raw material, and fixedly securing both the component parts by welding. Further, besides the above-mentioned method of manufacturing a drive plate, there are methods of manufacturing a drive plate comprising the steps of forming an outer peripheral portion of a disk-shaped thin plate material in a thick peripheral wall by folding as disclosed in Japanese Patent Publications Nos. SHO 54-44259 and SHO 54-20190 or spinning that portion as desclosed in West German Patent No. 38 19 957, and then forming gear teeth at the thick-walled peripheral portion. Out of the above-mentioned prior art methods, in the former method of manufacturing a drive plate from the two component parts, since the gear teeth of a gear member are formed by machining using a gear hobbing machine, the cost of the products will increase, and also since the two component parts are fixedly secured by welding, causing deformation of the products due to welding strain, it has been necessary to remove the welding strain throughout the whole welded joints. Whilst, in the latter method of manufacturing a drive plate by forming a thin plate into a dish-shaped portion and a gear portion integrally, it is difficult to form gear teeth, and also it is difficult to form the thick-walled peripheral portion having a uniform thickness. Particularly, in the method of forming the thick-walled peripheral portion by spinning, it is difficult to obtain a wall thickness enough to form gear teeth. Concerning further details of the present invention, the US-A 2 654 944 discloses manufacturing of gear teeth by pressing or forging instead of machining. The DE-A 3 715 392 mentions cold rolling of gear teeth on the inner peripheral surface of a hollow, cylindrical body. The FR-A 2 524 354 discloses cutting of gear teeth. The present invention has for its object to provide a method of manufacturing a drive plate, which is an improvement of the latter method in the above-mentioned prior art manufacturing methods of a drive plate comprising the steps of forming a dish-shaped portion on the side of a boss thereof and a gear portion on the side of an outer peripheral portion thereof integrally, wherein in the step of forming a disc-shaped thin plate material, a thick wall portion having a sufficient thickness can be formed at the outer peripheral portion thereof, and also gear teeth can be formed at the thick wall portion without having to carry out any after-machining. To comply with the object of the invention, the method according to the present invention is characterized by the features of claim 1. Particular embodiments of the invention are set out in the dependent claims. According to the present invention, there is provided a method of manufacturing a drive plate comprising the steps of swaging an outer peripheral portion of a disc-shaped raw material in the radial direction thereof in two steps so as to form the outer peripheral portion in a thicker wall portion as compared with the remainder thereof, holding said swaged material between an upper die and a lower die and pressing the material through the upper and lower dies so as to form it into a dish-shaped blank, and pressing radially the thick-walled outer peripheral portion of said dish-shaped blank held between a support die disposed either on the outside or on the inside thereof and a gear tooth profile forming die so as to form gear teeth either on the radially outside or on the radially inside of the outer peripheral portion. According to the present invention, in case of forming a disc-shaped thin plate material into a drive plate as an integral unit, a blank having a thick-walled portion of a sufficient thickness can be formed in the outer peripheral portion thereof by swaging the plate material, and also gear teeth can be formed on the outer peripheral portion of the swaged blank without having to carry out any after-machining. The above-mentioned and other objects, aspects and advantages of the present invention will become apparent to those skilled in the art by making reference to the following description and the accompanying drawings in which preferred embodiments incorporating the principles of the present invention are shown by way of example only. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a sectional view showing a condition of a disc-shaped thin plate material fixedly secured to a positioning pin so as to be subjected to swaging; Fig. 2 is a sectional view showing a first swaging process; Fig. 3 is a sectional view showing a second swaging process; Fig. 4 is a sectional view showing a blank forming process; Fig. 5 is a sectional view showing gear teeth profile forming process; Fig. 6 is a plan view showing principal parts of an outer tooth profile forming die and an inner support die for use in the gear teeth forming process; and Fig. 7 is a front elevational view showing one example of the gear tooth cold-rolling machine. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS The present invention will now be described in detail below by way of several embodiments thereof with reference to the accompanying drawings. As shown in Fig. 1, a disc-shaped thin plate material 1, which is obtained by punching a thin plate material of 2 to 3 mm thick in a disc-like shape, is fixedly secured with the radially inside of the material, where is not subjected to swaging process, hold between a fixing bed 2 and a pushing plate 3. At that time, positioning of the disc-shaped material 1 is made by fitting a positioning pin 4 mounted coaxially on the fixing bed 2 into a circular hollow portion 1b formed by punching around the axis of the material 1. Subsequently, as shown in Fig. 2, a radially outer peripheral portion 1a of the disc-shaped material 1 is subjected to a first swaging process by a first swaging die 5 which acts towards the axis of the material 1 in the radial direction. By this first swaging, the end of the outer peripheral portion of the material 1 is formed thinner than other outer peripheral portion. After that, as shown in Fig. 3, the swaged outer peripheral portion 1a is subjected to second swaging by a second swaging die 6 so that it is formed into a rectangular shape in section. Subsequently, as shown in Fig. 4, the thin plate-shaped portion of the swaged material 1' which has been subjected to the first and second swaging is formed into a dish-shaped member by a lower die 7 and an upper die 8. At that time, the outer peripheral portion of the swaged material 1' is regulated by an inner peripheral side wall 9 of the lower die 7. This forming results in a dish-shaped blank 10. Further, as the inner peripheral side wall 9, an outer die which is separate from the lower die 7 may be used. Next, for example, the swaged outer peripheral portion of the blank 10 is subjected to a cold die forging so that it is formed into an external gear. One example of this external gear forming process is shown in Fig. 5. The above-mentioned blank 10 is located coaxially inside of an external gear tooth profile forming die 11 having a gear tooth profile in the inner periphery thereof, and then a support die 12 is axially pressed into the radially inside of the blank 10 so that the outer peripheral portion 1a thereof which has been swaged is formed with external gear teeth. At that time, the outside diameter of the support die 12 is larger than the inside diameter of the dish-shaped blank 10, and when the support die 12 is pressed into the blank 10, the swaged outer peripheral portion 1a of the blank 10 is pressed out, thereby forming external gear teeth each corresponding to the gear tooth shape of the external gear tooth profile forming die 11 on the radially outside portion. Further, at that time, by forming the outer peripheral portion of the support die 12 in a wave shape 13 having the same pitch as that of the gear tooth profile of the external gear tooth profile forming die 11, as shown in Fig. 6, it has become possible to form the above-mentioned external gear teeth readily, and mass-produce large drive plates each having diameter of 200 mm or over, mass-production of which has been heretofore difficult. While in the above-mentioned embodiment there is shown a method of forming external gear teeth in the swaged outer peripheral portion 1a of the blank 10, by locating an internal gear profile forming die on the radially inside of the swaged outer peripheral portion 1a of the blank 10, and pressing the swaged outer peripheral portion 1a radially inwards by a support die, which is located on the radially outside thereof, in the process shown in Figs. 5 and 6, internal gear teeth can be formed along the radially inside of the swaged outer peripheral portion 1a of the blank 10. Furhter, while in each of the above-mentioned embodiments there is shown one example of the method of die forging gear teeth by means of the gear tooth profile forming die and the support die, the gear teeth may be formed along the swaged outer peripheral portion of the blank 10 using a gear tooth cold rolling machine 14 as shown in Fig. 7. This gear teeth cold rolling machine 14 is of a conventional type, and is arranged such that the blank 10 is held between a vertically movable table 15 and a pushing plate 16 which are located at the center of the apparatus, and cold rolling dies 18, 18 supported by supporting beds 17, 17 are thrust against the outer peripheral end face of the blank 10 so as to form rolled gear teeth. Yet further, the blank 10 which has been subjected to the process shown in Fig. 4 may be formed with internal gear teeth or external gear teeth by machining using a gear hobbing machine or the like. Further, the forming of the gear teeth may be made by a cold rolling process using fixed machine tools. It is to be understood that the foregoing description is merely illustrative of preferred embodiments of the present invention, and that the scope of the invention is not to be limited thereto, but is to be determined by the definition of the appended claims.

Claims: Method of manufacturing a drive plate comprising a blank forming process wherein a disc-shaped material is formed into a blank being disc-shaped and having a thick-walled outer peripheral portion and a gear teeth forming process wherein gear teeth are formed on an end face of said thick-walled outer peripheral portion, said blank forming process comprising a first swaging step for forming an outer peripheral portion of said disc-shaped material first into an acute-angled shape in section by swaging work using a first swaging die (5) and a second swaging step for forming said outer peripheral portion of said material next into a rectangular shape in section by swaging work using a second swaging die (6), characterized in that said blank forming process further comprises a pressing step wherein said material having the outer peripheral portion formed into a rectangular section are held between and pressed through upper and lower dies (8,7) so that said material is transformed to have a thick-walled outer peripheral portion to which said gear theeth are to be formed. Method of manufacturing a drive plate as claimed in claim 1, characterized in that said gear teeth are formed through forging work using a support die (12) and a gear tooth profile forming die (11). Method of manufacturing a drive plate as claimed in claim 2, characterized in that said support die (12) is disposed on the inside of said blank (10) and said gear tooth profile forming die (11) is disposed on the outside of said blank, and that when said thick-walled outer peripheral portion (1a) of said blank (10) is pressed through said support die (12) from the radially inside thereof towards the radially outside thereof, the radially outer peripheral end face of said thick-walled outer peripheral portion (1a) is formed with gear teeth. Method of manufacturing a drive plate as claimed in claim 2, characterized in that said support die (12) is disposed on the outside of said blank and said gear tooth profile forming die (11) is disposed on the inside of said blank (10), and that when said thick-walled outer peripheral portion of said blank is pressed through said support die (12) from the radially outside thereof towards the radially inside thereof, the radially inner peripheral end face of said thick-walled outer peripheral portion is formed with gear teeth. Method of manufacturing a drive plate as claimed in claim 3 or 4, characterized in that the peripheral end portion of said support die (12) is formed in a wave shape (13) having the same pitch as that of the gear teeth formed in said gear tooth profile forming die (11). Method of manufacturing a drive plate as claimed in claim 1, characterized in that said gear teeth are formed through cold rolling work or gear tooth cutting work using a gear hobbing machine or a gear tooth cutting machine.

Inventors: YAMANAKA SHIGEAKI, YAMANAKA, SHIGEAKI
Applicants: KUBOTA IRON WORKS CO LTD, KUBOTA IRON WORKS CO., LTD.
Application year: 1991
Main classification: B21D53
IPC codes: C23C14, B21J5, B21K1, B21H5, B21D53