Cold-formed shapes supplied with the desired geometric form enables the customer to reduce their production costs. However a good knowledge of the material and heat treatment technology as well as a sophisticated tool making process is required. A basic comment is made on the drawing process, the dies manufactured for drawing shapes and the advantages of cold-drawn shapes. Two examples of cold-formed shapes for high performance components - Rocker Pins and Sprags - are illustrated in this paper. Rocker Pins are used in the belt / chain of Continuous Variable Transmission (CVT) gears in passenger cars. In this gear the power is transferred by friction of the rocker pins between two sets of cone pulley discs. High torques of over 300 Nm can be achieved by such a gear. The demands on the cold-formed rocker pins are very stringent regarding the dimensional control, strength, surface quality and defects. Sprags are transmission elements for freewheel drives. A prerequisite for the functionality and robustness of these elements are very narrow tolerances, uniformity of the mechanical properties and good surface quality. To achieve the demanded zero defect goal, the manufacturing process must have a high capability index and the final product must undergo a 100%-test for detecting surface defects.
Cold-formed shapes for high performance automotive components
Kaltumgeformte Profile für hochwertige Fahrzeugbauteile
2005
7 Seiten, 6 Bilder, 6 Quellen
Aufsatz (Konferenz)
Englisch
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