SPLINE ROLLING RACK AND METHOD
A spline rolling rack assembly for cold-forming external surface configurations upon a metal workpiece is provided, having a durable carriage of the type secured upon a reciprocating slide assembly, a perishable rack insert that is removably secured upon the carriage, a locating key disposed between the rack insert and the carriage for properly aligning the rack insert upon the carriage, a locating assembly disposed upon the carriage and engageable with the rack insert for assisting in properly aligning the rack insert and the carriage between load and work positions, and multiple clamping assemblies disposed within said carriage for releasably securing the rack insert upon the carriage. The perishable rack insert is designed for quick and convenient replacement, reducing maintenance cost and idle time for these devices. The single-use nature of the insert relieves the user from the burden of managing an inventory of like tools, in various states of use, in order to ensure that new tools are ordered in a timely manner for replacing tools that have exhausted their useful life.
This application is a continuation of U.S. patent application Ser. No. 13/478,663 filed on May 23, 2012. The entire disclosure of the above application is incorporated herein by reference.
FIELDThe present disclosure relates generally to machines for forming external surface configurations upon metal workpieces by pressure-applied material displacement, and is more specifically directed to spline rolling rack assemblies, components, tooling and devices for securing and manipulating such tooling. The present disclosure also relates to methods for roll-forming splines on the external surfaces of axle, shaft and other power/torque transmission components of the type used in vehicles, machines, commercial and industrial equipment and other devices.
BACKGROUNDThis section provides background information related to the present disclosure which is not necessarily prior art.
The manufacture of axle, shaft and other power/torque transmission components of the type used in vehicles, machines, commercial and industrial equipment and other devices often requires the formation of power/torque transmission features upon the external surfaces of round metal workpieces, in the form of rods, tubes, cylinders and other shapes. One exemplary manufacturing method involves spline rolling, which typically utilizes a pair of opposed, elongated, substantially parallel, reciprocating dies, tools or tool members (called “racks”) having a series of feature-forming surfaces, such as teeth, disposed in precision arrangements on facing surfaces thereof corresponding to, but not necessarily matching, the desired final surface features of the workpiece to be prepared. Accordingly, spline rolling typically involves reciprocating movement of the opposed dies, tools or tool members (called “racks”) over the length of a rotating workpiece, in opposite directions and in overlapping relationship, causing the feature-forming surfaces to displace material upon the surface of the rotating workpiece by applied pressure, in a cold-forming technique. The spline rolling operation thus forms the desired finished external surface features in the workpiece, typically helical or spur ridges, teeth or grooves (or “splines”), through the combination of the rotation of the workpiece with the linear reciprocating movement of the racks. Spline rolling racks are typically constructed in single or double-piece form, with either the single piece or both pieces of a double-piece rack being perishable. They are typically fastened upon suitable opposed, elongated, substantially parallel, reciprocating slide assemblies located within dedicated spline rolling machines of industrial grade.
The nature of forming the desired power/torque transmission features, such as splines, requires critical tolerances in the size and configuration of the feature-forming surfaces, and well as in the spacing, configuration and movement of the racks so that the desired surface features are accurately formed in the workpiece. Thus, these tooling components require precision-crafted feature-forming surfaces and precision mounting apparatus, supports and fasteners within the larger machines in which they are typically contained. However, these tooling components have a limited lifespan, with their feature-forming surfaces typically becoming worn or no longer within required tolerances after some period of their use.
Accordingly, at periodic intervals it is typically necessary to remove the surface-forming tooling components for replacement or resurfacing. Such components can typically be resurfaced a number of times before they can no longer be resurfaced, and as such, must then be replaced. Oftentimes, the manufacture and resurfacing of such tooling components is inefficient due to the time required to ship the components back to the manufacturer for resurfacing and back again to the user. Also, oftentimes, removal and replacement of such tooling components is time-consuming, burdensome and otherwise inefficient, due to the configuration and large size of the components, the current way in which the tooling components are secured in a work position, and the positioning and aligning activities that must typically take place for securing the components in a work position. Having such a machine in an idle state during required maintenance activities slows down overall production rates for any such affected facility, so it is advantageous for such maintenance to be made convenient, efficient and quick.
As examples, the tooling components requiring repair or replacement may be secured within the interior of a larger machine in a way that is inconvenient to manage, such as being secured with fasteners, such as bolts and set screws, that are difficult to reach and manipulate. In addition, the end of a spline rolling rack is typically the primary locating surface for gauging the proper mounting location of the rack within the machine, which can be inconvenient to measure or check for proper alignment. Also, the tooling components may not themselves be manufactured in sufficient tolerances for precision work, or the devices or features provided for facilitating proper positioning may not be sufficient or efficient to use. Proper alignment of the tooling components relative to each other must typically be ensured, which may only be provided in limited scope by relative adjustment of certain surfaces on the machine components when located within the machine that can be difficult to reach and/or examine. The final tolerances required in the feature-forming surfaces may also not be sufficient, or may be manufactured inefficiently, such as by preparing the feature-forming surfaces to required precision tolerances as the final step of the manufacturing process.
In addition, there is typically a substantial cost associated with the replacement or repair of the tooling components involved in such surface forming operations. The sizes of the components can be substantial, depending upon the sizes of the power/torque transmission components being manufactured, perhaps requiring substantial powered lifting equipment for assisting in this activity. The repair or replacement of the tooling components may require shipment and/or courier delivery of substantially-sized and weighted components, at considerable expense. Users of such tooling components must also manage a float of such tools at various levels of life and, due to the lead time required to manufacture new racks, must anticipate tools ending their life span and order new tools to arrive in conjunction with the retirement of existing tools.
In consideration of the above, the adoption of an improved configuration of such surface-forming tooling components along with an improved configuration of the associated devices used for retaining such components in required locations while maintaining the required tolerances for same, would provide significant maintenance efficiencies and cost benefits.
SUMMARYThis section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
The present disclosure provides a spline rolling rack assembly for cold-forming external surface configurations upon a metal workpiece, comprising a durable carriage operable for being fixedly secured upon a reciprocating slide assembly within a machine for forming external surface configurations upon said metal workpiece. The carriage includes a mounting surface and is operable for sliding in reciprocating relation together with rotation of the workpiece. The spline rolling rack assembly further comprises a perishable rack insert that is operable for being removably secured upon said mounting surface of said carriage, the rack insert having a working surface with a series of feature-forming surfaces formed thereupon for cold-forming external surface configurations upon a metal workpiece. The rack insert is operable for being removed from, and secured upon, the carriage within the machine without removing the carriage from within the machine.
The spline rolling rack assembly further comprises a locating key operable for being disposed between a first locating key recess formed within the rack insert and a second locating key recess formed within the carriage for properly aligning the rack insert upon the carriage in at least one of a load position and a work position. Manufactured configurations of the locating key and the first and second locating key recesses together comprise the primary engaging components and surfaces for properly aligning said rack insert upon said carriage in at least one of a load position and a work position. Also, the locating key may preferably be secured to said carriage by a locating bolt.
The spline rolling rack assembly further comprises a locating assembly operable for being disposed upon the carriage in movable relation between a first position corresponding to a loading position of the rack insert upon the carriage and a second position corresponding to a work position of the rack insert upon said carriage. The locating assembly is also operable for engaging a recess within the rack insert, wherein movement of the locating assembly from the first position to the second position engages the locating assembly with the recess within the rack insert to assist in properly aligning the rack insert upon the carriage in at least one of a load position and a work position.
The spline rolling rack assembly further comprises a plurality of clamping assemblies disposed at spaced apart locations longitudinally within the carriage, each clamping assembly operable for releasably contacting the rack insert in a pressurized manner for securing the rack insert in a fixed work position upon the carriage, wherein each clamping assembly is operable for being adjusted between a released unclamped condition and an engaged clamped condition.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. It will be appreciated that the above principles may be applied to devices for forming other types of external surface configurations upon other workpieces as well.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTIONExample embodiments will now be described more fully with reference to the accompanying drawings.
The spline rolling rack assembly 10 also includes a rack insert 16 having a working surface 18 that includes a plurality of feature-forming surfaces, shown in the form of teeth 20, formed upon the working surface 18. It will be appreciated that any other suitable feature-forming surfaces may also be formed upon the working surface 18, depending on the surface configurations desired upon the workpiece. The rack insert 16 is designed to be removably secured upon the carriage mounting surface 14 in a quick and convenient way, without requiring the use of extensive bolts or other individual fasteners. Accordingly, the rack insert 16 is intended to be quickly and conveniently removed from its position upon the carriage 12, and replaced into its position and secured upon the carriage 12, whenever repair or replacement of the rack insert 16 is required. The present invention thus provides a dual-component assembly wherein the carriage 12 remains within the larger machine, while only the rack insert 16 is removed and replaced. The configurations and dimensions of the feature-forming surfaces, the carriage 12 and the remainder of the rack insert 16 are manufactured to precision tolerances in configurations and dimensions as may be necessary for creating the required tolerances of configurations and dimensions in the surface configurations being formed upon the workpiece.
The present arrangement therefore contemplates eliminating use of prior perishable single-piece racks or a double-piece racks wherein both pieces are perishable in favor of a two-piece tooling assembly having a durable carriage supporting a perishable rack insert. Such an arrangement is believed to greatly enhance the convenience and speed for removing and replacing the rack inserts 16, which in turn will reduce the time that the spline rolling machine is idle for maintenance. In addition, the rack inserts 16 are preferably designed for a single use, although they may also be refinished and reused as many times as permitted by the required specifications and tolerances of the tooling equipment being used and the workpieces being treated. Because the rack inserts 16 can be of significantly smaller dimensions than a single-piece rack of the type common in previous devices, the new rack inserts 16 of the present invention can be handled and shipped much more quickly, more conveniently and at lower cost.
As shown in
The spline rolling rack assembly 10 further includes a locating assembly, generally at 30. The locating assembly 30 includes a lock pin 32 attached to a lock shaft 34 that is rotatably disposed within a first locating assembly recess 36 of the carriage 12. It will be appreciated that multiple lock pins 32 may be employed, depending on the application. The lock pin 32 extends from the lock shaft 34 outwardly from within the first locating assembly recess 36 of the carriage 12 to within a second locating assembly recess 38 of the rack insert 16, which forms a stop for movement of the rack insert 16 once it reaches a work position. The lock pin 32 and lock shaft 34 are together capable of being rotated between a first position corresponding to a load position of the rack insert 16 upon the carriage 12 (represented by the position of the lock pin 32 in
The components of the locating assembly 30 are shown in greater detail with reference to
The various operating positions of the locating assembly 30 are shown in greater detail with reference to
Referring again to
The components and functions of the clamping assemblies will be discussed in greater detail with reference to
The cam 58 and clamp pin 60 are shown in a clamped work condition in
As shown in the longitudinal views of
In the method of the present disclosure, the rack insert 16 is positioned upon the mounting surface 14 of the carriage 12 in such a manner that the load arrows 35 and 37 are aligned, as shown in
Securing the assembly in the clamped working position also requires the release of cam 58 in each clamping assembly 48, 50, 52 and 54 by engaging the Allen wrench recess 63 with a suitable Allen wrench and rotating the cam 58 in either a clockwise or counter-clockwise direction within the lock pin recess 61 such as to the position marked as 58 in the embodiment shown in
Removal of the rack insert 16 from upon the carriage 12 involves releasing each clamping assembly 48, 50, 52 and 54 from the clamped to the unclamped condition while the overall assembly is in the working position. To accomplish this (for each clamping assembly), the Allen wrench recess 63 is engaged with a suitable Allen wrench and rotated clockwise or counter-clockwise within the lock pin recess 61, which causes the clamp pin 60 to travel toward the rack insert 16, releasing the clamp pin 60 from bearing upon the clamping assembly recess 56 and unclamping the assembly. The assembly is then moved from the working position to the loading position by actuating the locating assembly 30 by the engagement of Allen wrench recess 31 with a suitable Allen wrench, so that the lock shaft 34 may be depressed and then rotated clockwise, moving the rack insert 16 longitudinally relative to the carriage 12 into the loading position shown in
Since typical spline rolling racks include upper and lower spline rolling rack assemblies such as the assembly described herein, it will be appreciated that the above description of both apparatus and method typically apply to both an upper and lower assembly, which must both be installed and secured before operation of the overall spline rolling rack machine can begin.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
Claims
1. A spline rolling rack assembly for cold-forming external surface configurations upon a metal workpiece, comprising:
- a durable carriage operable for being fixedly secured upon a reciprocating slide assembly within a machine for forming external surface configurations upon said metal workpiece, said carriage having a mounting surface, said carriage operable for sliding in relation together with rotation of the workpiece;
- a perishable rack insert operable for being removably secured upon said mounting surface of said carriage, said rack insert having a working surface with a series of feature-forming surfaces formed thereupon for forming external surface configurations upon a metal workpiece and a locking bearing surface, said rack insert operable for being removed from, and secured upon, said carriage within said machine without removing said carriage from within said machine;
- a locating key operable for being disposed between a first locating key recess formed within said rack insert and a second locating key recess formed within said carriage for properly aligning said rack insert upon said carriage in at least one of a load position and a work position, wherein manufactured configurations of said locating key and said first and second locating key recesses together comprise the primary engaging components and surfaces for properly aligning said rack insert upon said carriage in at least one of a load position and a work position, and wherein said locating key is secured to said carriage;
- a locating assembly operable for being disposed upon said carriage in movable relation between a first position corresponding to a loading position of said rack insert upon said carriage and a second position corresponding to a work position of said rack insert upon said carriage, said locating assembly also operable for engaging a recess within said rack insert, wherein movement of said locating assembly from said first position to said second position engages said locating assembly with said recess within said rack insert to assist in properly aligning said rack insert upon said carriage in at least one of a load position and a work position, wherein said locating assembly comprises a lock pin attached to a lock shaft rotatably disposed within said carriage and capable of being rotated between a first position corresponding to a load position of said rack insert upon said carriage and a second position where the locking shaft engages a tapered surface of the insert corresponding to a work position of said rack insert upon said carriage; and
- a plurality of clamping assemblies disposed at spaced apart locations longitudinally within said carriage, each clamping assembly having a translatable locking member with an annular engagement surface configured to engage the locking bearing surface of the rack insert, the translatable locking member having a shaft defining a cam following surface, said clamping assemblies each having a rotatable member disposed generally perpendicular to the shaft and having a cam configured to engage the cam following surface upon rotation of the rotatable member in a first direction, the translatable member being operable for releasably contacting said rack insert in a pressurized manner for securing said rack insert in a clamped work position upon said carriage, wherein each clamping assembly is operable for being adjusted between a released unclamped condition and an engaged clamped condition, wherein said locating assembly comprises a lock member attached to a lock shaft rotatably disposed within said carriage and capable of being rotated between a first position corresponding to a load position of said rack insert upon said carriage and a second position corresponding to a work position of said rack insert upon said carriage.
2. A spline rolling rack assembly according to claim 1, wherein each clamping assembly comprises a surface disposed within said carriage and operable for engaging a clamp pin which forms part of the clamping.
3. A spline rolling rack assembly according to claim 2, wherein each clamping assembly is operable for engaging a recess within the rack insert, and wherein adjustment of said clamping assembly from a released unclamped condition to an engaged clamped condition operates to engage the clamp pin forming part of the clamping assembly against said recess within said rack insert.
4. A spline rolling rack assembly according to claim 1, wherein said carriage includes longitudinally disposed inner and outer datum rails for engaging a member upon said rack insert in close fit relation to assist in properly aligning said rack insert upon said carriage in at least one of a load position and a work position.
5. A spline rolling rack assembly according to claim 1, wherein said rack insert further comprises an inner datum surface locations said feature-forming surfaces when said rack insert is in said work position.
6. A spline rolling rack assembly according to claim 1, wherein said locating key and said first and second locating key recesses operate to enhance the location of said feature-forming surfaces when said rack insert is in said work position.
7. A spline rolling rack assembly according to claim 1, wherein said rack insert selectively wears and is intended for disposal after said working surface becomes worn.
8. A spline rolling rack assembly according to claim 1, wherein said locating key is secured to said carriage.
9. A spline rolling rack assembly according to claim 1, wherein said rack insert and said carriage each include load alignment indicia on corresponding surfaces for indicating when the rack insert and the carriage are aligned in a load position.
10. A spline rolling rack assembly according to claim 1, wherein said rack insert comprises at least one height location datum in contact with the carriage during operation.
11. A spline rolling rack assembly according to claim 10, wherein said rack insert comprises inner and outer height location datums which are mounted upon, and correspond to, inner and outer datum rails formed upon the carriage.
12. A spline rolling rack assembly according to claim 1, wherein said external surface configurations formed upon a metal workpiece are in the form of splines.
13. A spline rolling rack assembly for cold-forming external surface configurations upon a metal workpiece, comprising:
- a durable carriage operable for being fixedly secured upon a slide assembly within a machine for forming external surface configurations upon said metal workpiece, said carriage having a mounting surface, said carriage operable for sliding in reciprocating relation together with rotation of the workpiece;
- a perishable rack insert operable for being selectively secured upon said mounting surface of said carriage, said rack insert having a working surface with a series of feature-forming surfaces formed thereon for cold-forming external surface configurations upon a metal workpiece, said rack insert defining a coupling aperture holding an insert bearing plate that defines a bearing surface, said rack insert operable for being removed from, and secured upon, said carriage within said machine without removing said carriage from within said machine;
- a locating key operable for being disposed between a first locating key recess formed within said rack insert and a second locating key recess formed within said carriage for properly aligning said rack insert upon said carriage in at least one of a load position and a work position, wherein manufactured configurations of said locating key and said first and second locating key recesses together comprise the primary engaging components and surfaces for properly aligning said rack insert upon said carriage in at least one of a load position and a work position; and
- a plurality of clamping assemblies disposed on said carriage, each clamping assembly having a translatable locking member with an engagement surface configured to engaged the ramped bearing surface of the rack insert, the translatable locking member having a shaft defining a cam following surface, said clamping assemblies each having a member disposed generally perpendicular to the shaft and having a cam configured to engage the ramped bearing surface upon movement of the rotatable member in a first direction, the translatable member being each clamping assembly operable for releasably contacting said rack insert in a compressive manner for securing said rack insert in a fixed work position in said carriage.
14. A spline rolling rack assembly for cold-forming external surface configurations upon a metal workpiece, comprising:
- a durable carriage operable for being fixedly secured upon a reciprocating slide assembly within a machine for forming external surface configurations upon said metal workpiece, said carriage operable for sliding in reciprocating relation together with rotation of the workpiece;
- a perishable rack insert operable for being removably secured upon said carriage, said rack insert having a working surface with a series of feature-forming surfaces formed thereupon for cold-forming external surface configurations upon a metal workpiece, said rack insert defining a coupling bearing surface, said perishable rack insert being operable for being removed from, and secured upon, said carriage within said machine without removing said carriage from within said machine; and
- a plurality of clamping assemblies having a selectively rotatably translatable member with a ramped annular engagement surface configured to engage the coupling bearing surface of the rack insert, the selectively translatable member having a cam following surface, said clamping assemblies each having a movable member disposed generally perpendicular to the shaft and having a cam configured to engage the cam following surface upon translation of the translatable member in a first direction, the selectively translatable member being operable for releasably contacting said rack insert in a compressive manner for securing said rack insert in a fixed work position upon said carriage, wherein each clamping assembly is operable for being adjusted between a released unclamped condition and an engaged clamped condition.
15. A method for preparing a spline rolling rack assembly for cold-forming external surface configurations upon a metal workpiece comprising the steps of:
- providing a durable carriage fixedly secured upon a reciprocating slide assembly within a machine for forming external surface configurations upon said metal workpiece;
- providing a perishable rack insert defining a clamping assembly having a selectively engagable bearing surface operable for being removably secured upon a mounting surface of said carriage;
- disposing a locking member defining a bearing surface adjacent the selectively engagable bearing surface;
- positioning said rack insert upon said mounting surface of said carriage, so as to engage a locating key secured upon said carriage with a locating key recess disposed within said rack insert, to engage a locating assembly disposed upon said carriage with a locating assembly recess disposed within said rack insert, and also to engage at least one clamping assembly disposed upon said carriage with the selectively engagable bearing surface, wherein said locating assembly comprises a lock pin attached to a lock shaft rotatably disposed within said carriage and capable of being rotated between a first position corresponding to a load position of said rack insert upon said carriage and a second position where the locking shaft engages a tapered surface of the insert corresponding to a work position of said rack insert upon said carriage;
- actuating said locating assembly to move said rack insert longitudinally relative to said carriage into a working position, to engage said locating key against a primary stop surface forming part of said locating key recess, and also to place said clamping assembly in a configuration to be secured into a clamped condition; and
- securing said at least one clamping assembly into a clamped condition between said carriage and said rack insert.
16. The method for preparing a spline rolling rack assembly according to claim 15, wherein the step of positioning said rack insert upon said carriage comprises engaging a plurality of clamping assemblies between said carriage and said rack insert.
17. The method for preparing a spline rolling rack assembly according to claim 15, wherein the step of positioning said rack insert upon said carriage causes a clamp pin protruding from said carriage to engage a large radius recess forming part of said clamping assembly recess in said rack insert.
18. The method for preparing a spline rolling rack assembly according to claim 17, wherein the step of actuating said locating assembly causes said clamp pin to switch from engaging said large radius recess to engaging a small radius recess forming part of said clamping assembly recess in said rack insert.
19. The method for preparing a spline rolling rack assembly according to claim 18, further comprising securing said clamp pin against said small radius recess.
20. The method for preparing a spline rolling rack assembly according to claim 15, further comprising causing a lock pin to move from a first load position to a second work-unclamped position and subsequently to a third work-clamped position between said carriage and said rack insert.
21. A perishable rack insert operable for use as part of a spline rolling rack assembly for cold-forming external surface configurations upon a metal workpiece, said rack insert comprising:
- a working surface with a series of feature-forming surfaces formed thereupon for cold-forming external surface configurations upon said metal workpiece; and
- said rack insert defining an aperture having a ramped bearing surface operable for being removably secured upon a durable carriage fixedly secured upon a reciprocating slide assembly within a machine for forming external surface configurations upon said metal workpiece, without removing said carriage from within said machine.
22. A method for preparing a spline rolling rack assembly for cold-forming external surface configurations upon a metal workpiece comprising the steps of:
- providing a durable carriage support having a plurality of coupling mechanisms, said durable carriage support being fixedly secured upon a reciprocating slide assembly within a means for forming external surface configurations upon said metal workpiece;
- providing a perishable rack insert operable for being removably secured upon a mounting surface of said carriage, said perishable rack insert defining an annular ramped coupling bearing surface;
- positioning said rack insert upon said mounting surface of said carriage;
- securing said rack insert to the coupling mechanism upon said mounting surface of said carriage without removing said carriage from within said machine; and translating the coupling mechanism to engage the coupling bearing surface of the rack insert.
Type: Application
Filed: Jul 28, 2016
Publication Date: Nov 17, 2016
Inventor: Michael David Callesen (Columbia Station, OH)
Application Number: 15/221,677