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EP0137957B1 - Method of manufacturing an intermediate stage for a commutator-segment collar - Google Patents

Method of manufacturing an intermediate stage for a commutator-segment collar Download PDF

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Publication number
EP0137957B1
EP0137957B1 EP84109726A EP84109726A EP0137957B1 EP 0137957 B1 EP0137957 B1 EP 0137957B1 EP 84109726 A EP84109726 A EP 84109726A EP 84109726 A EP84109726 A EP 84109726A EP 0137957 B1 EP0137957 B1 EP 0137957B1
Authority
EP
European Patent Office
Prior art keywords
forming
punch
intermediate stage
longitudinal axis
blank
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
EP84109726A
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German (de)
French (fr)
Other versions
EP0137957A1 (en
Inventor
Fritz Prof. Dr.-Ing. Dohmann
Peter Franz
Friedrich Dipl.-Ing. Klaas
Günter Schulze
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Robert Bosch GmbH
Original Assignee
Robert Bosch GmbH
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Filing date
Publication date
Application filed by Robert Bosch GmbH filed Critical Robert Bosch GmbH
Publication of EP0137957A1 publication Critical patent/EP0137957A1/en
Application granted granted Critical
Publication of EP0137957B1 publication Critical patent/EP0137957B1/en
Expired legal-status Critical Current

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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/06Manufacture of commutators
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21KMAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K21/00Making hollow articles not covered by a single preceding sub-group
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21KMAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K23/00Making other articles
    • B21K23/04Making other articles flanged articles
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49002Electrical device making
    • Y10T29/49009Dynamoelectric machine
    • Y10T29/49011Commutator or slip ring assembly

Definitions

  • the invention is based on a method for producing a commutator segment ring according to the preamble of the main claim.
  • a method is already known in which bevels are formed at the ends of a straight workpiece and the workpiece is formed into an annular blank with mutually opposite ends forming a gap.
  • the blank is placed in a forming tool, aligned with one of the teeth of an inner punch forming the segment partial grooves, and formed into a commutator segment ring with a plurality of axial inner ribs forming commutator segments and a flange at one end.
  • the inner ribs remain connected by narrow webs that curve outwards.
  • the gap in the blank should run along a web.
  • the method has the disadvantage that when the blank is formed into the commutator segment ring - for example by extrusion - the gap repeatedly runs out of the area of the straight web due to the relatively long path of the material and the high forming forces.
  • the invention has for its object to provide a method with which an annular blank with its gap extending over its entire length can be cold formed waste-free into an intermediate stage with a hollow cylindrical shaft and flange, the gap maintaining its course to the longitudinal axis of the intermediate stage.
  • the blank is first formed into an intermediate stage with a hollow cylindrical shaft and flange at one end without a beveled ends forming a positioning groove, which enclose a gap, the flange already having the height and the shaft approximately the length of the later commutator segment ring receive.
  • Simple means are provided on the forming tool, with which a groove is formed at least on the shaft of the intermediate stage and the material flow is guided in such a way that the gap of the intermediate stage runs within the groove in a plane which extends radially through the longitudinal axis of the intermediate stage.
  • the means provided for guiding the material flow are particularly advantageously designed as a rib on at least part of the forming tool with which the groove is formed.
  • anchoring means for the later commutator segments can advantageously be integrally formed in the insulating material hub on the end face of the flange.
  • FIG. 1 shows a material section and FIG. 2 shows a blank bent from the material section, each in spatial representation, FIGS. 3 to 10 show an intermediate stage with modifications, and FIG. 11 shows a forming tool with an intermediate stage at the end of the forming process, in each case in longitudinal section.
  • the ends of the material section lie opposite each other and enclose a gap in the form of a butt joint 3.
  • the material section 1 can have a rectangular or round cross section.
  • An intermediate stage 4 for a commutator segment ring is formed from the blank 2 in a forming tool (FIGS. 3 to 10).
  • the intermediate stage 4 has a sleeve-shaped shaft 5 and a flange 6 at one end
  • An intermediate stage without a flange or a disc-shaped intermediate stage for a flat commutator segment ring can be produced from the “open blank 2” using a correspondingly modified forming tool.
  • the forming tool for backward hollow extrusion presses (FIG. 11) has a lower punch plate 7 with a die 8.
  • a bore 9 is formed in the die 8, which is continued in the lower punch plate 7 and in which a hollow punch-shaped ejector 10 is movably guided.
  • the ejector 10 sits when the blank 2 is inserted and during the forming to the intermediate stage 4 on the bottom 11 of the bore 9 and is displaceable by a plunger 12.
  • the ejector 10 is provided with a longitudinal bore 13 in which an inner punch 14 is movably received.
  • the cylindrical inner punch 14 also sits on the bottom 11 of the bore 9 when the blank 2 is inserted and is provided with a stroke-limiting stop 15.
  • a forming stamp 17 is fixedly arranged in a stamping plate 16 of the forming tool and can be moved with the stamping plate 16.
  • the forming die 17 has a sleeve-shaped end section 18 which can be moved into the die 8 as an extrusion die.
  • a counter-punch 20 is guided so as to be longitudinally movable and can be moved towards the lower die plate 7 relative to the shaping die 17 and the upper die plate 16 by a die 21 movably arranged in the upper die plate 16.
  • the counter-punch 20 serves as a counterhold at the end of the shaft 5 of the intermediate stage 4.
  • the counter-stamp 20 enables the cross-section of the intermediate stage 4 to be fully formed at the end of the shaft 5 through its hollow cylindrical end section 22, because its inside diameter can be somewhat larger than the outer diameter of the inner die 14 and the escape of a small amount of material into the annular gap between the dies 20 and 14.
  • the counter stamp 20 can serve as an additional ejector if the intermediate stage 4 should get caught on the forming stamp 17, 18.
  • a plunger 23 in the form of a screw with which the end position of the counter-punch 20 in the forming die 17 and the upper die plate 16 can be adjusted.
  • the plunger head also serves as an upper stop to limit the movement of the inner punch 14.
  • the butt joint 3 When shaping the blank 2 into the intermediate stage 4, the butt joint 3 must be maintained as a straight gap which runs parallel to the longitudinal axis of the intermediate stage 4 in a plane extending radially through the longitudinal axis. Only then can a commutator ring be formed from the intermediate stage 4 in a subsequent method known per se and not shown in detail, in which the gap runs only in one segment partial groove and does not escape into the adjacent segments. Simple means are therefore provided on the forming tool to direct the material flow during the forming of the blank 2 into the intermediate stage 4. At least on the shaft 5 of the intermediate stage 4, they form a groove in which the gap runs.
  • a longitudinal groove 24 is formed in the inner jacket 25, in which the gap 3 runs.
  • the inner punch 14 of the tool has a longitudinal rib 26 on the jacket.
  • the ejector 10 and the counter punch 20 are provided with a corresponding longitudinal groove 27 and 28, respectively.
  • the longitudinal groove 24 is continued in a radial groove 29 on the end face 30 of the flange 6.
  • the ejector 10 is provided on its end face with a radial rib 31 which runs in the same radial plane through the longitudinal axis of the intermediate stage 4 and thus of the forming tool as the longitudinal rib 26 of the inner punch 14.
  • the gap 3 in the flange 6 thus runs in the radial groove 29 .
  • a longitudinal groove 32 is formed on the outer jacket 33 in the intermediate stage 4.
  • the end section 18 of the forming die 17 is provided with a longitudinal rib 34.
  • a longitudinal groove 35 is provided in the counter-punch 20.
  • the longitudinal groove 32 is continued in a radial groove 36 on the rear side 37 of the flange 6, in which the gap 3 runs in the flange 6.
  • the end section 18 of the forming die 17 is provided on its end face with a rib 38 which adjoins the longitudinal rib 34 radially.
  • a longitudinal groove 24 and 32 are formed on the shaft.
  • the shaping tool is equipped with the inner punch 14 with a longitudinal rib 26 and the shaping punch 17, 18 with a longitudinal rib 34.
  • the grooves 24, 29 and 32, 36 are formed in combination. Other combinations of the grooves are also possible.
  • the intermediate stage 4 is provided with an annular groove 39 on the end face 30 of the flange 6.
  • the ejector 10 of the forming tool is provided with a corresponding annular projection 40 on its end face for shaping the annular groove 39.
  • FIG. 10 A modification of the intermediate stage 4 according to FIG. 9 is shown in FIG. 10.
  • An annular extension 41 is formed on the end face 30 of the flange 6.
  • the ejector 10 of the forming tool is provided with an enlarged end section 42 of the longitudinal bore 13 for producing the extension 41.
  • annular groove 39 and the extension 41 already form additional anchoring means of the segments formed on the intermediate stage 4 emerge from a commutator segment ring to be produced in a subsequent method.
  • An insulating material hub in which the segments of the commutator are anchored, lies with a collar on the end face 30 of the later segments and engages with a clamp in the annular groove 39 or around the extension 41.
  • the blank 2 is inserted into the opened forming tool and aligned.
  • the upper stamp plate 16 with the forming stamp 17 and the counter stamp 20 is lifted off the lower stamp plate 7 with the die 8, ejector 10 and inner stamp 14, so that the end section 18 of the forming stamp 17 is at a sufficient height above the top, that is Receiving surface 43 of the die 8 stands.
  • the end faces of the forming die 17, 18 and counter-die 20 lie in one plane.
  • the inner die 14 and the ejector 10 are on the bottom 11 of the bore 9 in the die 8 and the lower die plate 7.
  • the blank 2 is pushed over the inner die 14 onto the ejector 10, the butt joint 3 the blank 2 on the longitudinal rib 26 of the inner die 14 aligns.
  • alignment means known per se and not shown in detail are provided.
  • the upper stamp plate 16 is now lowered until the end section 18 of the forming stamp 17 with the counter-stamp 20 rests on the blank 2.
  • the forming die 17, 18 is then pressed onto the blank 2, so that the intermediate stage 4 is formed by backward hollow extrusion.
  • the forming die 17, 18 forms the flange 6 at the level of the commutator segment ring to be produced later from the intermediate stage 4 in a manner known per se.
  • the material of the blank 2 which escapes into the hollow-cylindrical space enclosed by the inner punch 14, end section 18 and counter-punch 20 is shaped into the shaft 5.
  • the length of the shaft 5 is determined by the counter-stamp 20, which is under the influence of a counterforce acting on the stamp 21.
  • the inner ram 14, which is freely movable in the ejector 10, is entrained in the shaft 5 and thus in the shaping rams 17, 18 when the shaft 5 is formed by the friction forces occurring between the inner ram 14 and the shaft 5, and forms the longitudinal groove 24 with its longitudinal rib 26.
  • the material flow is guided by the longitudinal rib 26 in such a way that the butt joint 3 is expanded to form a straight gap which runs in the longitudinal groove 24 parallel to the longitudinal axis of the intermediate step 4 in a plane extending radially through the longitudinal axis (FIG. 11 with intermediate step 4 according to FIG. 3) ).
  • the upper stamp plate 16 with the forming stamp 17, 18 is moved back into the starting position.
  • the ejector 10 pushes the intermediate stage 4 from the inner die 14, which returns to its initial position on the bottom 11 of the bore 9 and out of the die 8. If the intermediate stage 4 gets caught in the forming die 17, 18, the counter-die 20 acts as an additional ejector before it is moved back to its original position. After ejection, the ejector 10 also returns to its starting position.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Motor Or Generator Current Collectors (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Forging (AREA)

Description

Stand der TechnikState of the art

Die Erfindung geht von einem Verfahren zum Herstellen eines Kommutatorsegmentringes nach der Gattung des Hauptanspruchs aus. Aus der DE-C2-25 09 107 ist schon ein Verfahren bekannt, bei dem an den Enden eines geraden Werkstücks Schrägen ausgebildet werden, und das Werkstück zu einem ringförmigen Rohling mit sich parallel gegenüberliegenden und einen Spalt bildenden Enden geformt wird. Der Rohling wird in ein Umformwerkzeug eingelegt, an einem der die Segmentteilnuten bildenden Zähne eines Innenstempels ausgerichtet und in einen Kommutatorsegmentring mit einer Vielzahl Kommutatorsegmente bildener axialer Innenrippen und einem Flansch an einem Ende umgeformt. Die Innenrippen bleiben durch nach außen gewölbte schmale Stege verbunden. Der Spalt im Rohling soll dabei entlang eines Steges verlaufen. Bei dem Verfahren ist jedoch von Nachteil, daß beim Umformen des Rohlings in den Kommutatorsegmentring - beispielsweise durch Fließpressen - der Spalt immer wieder aus dem Bereich des geraden Steges herausläuft bedingt durch den verhältnismäßig langen Weg des Werkstoffs und die hohen Umformkräfte.The invention is based on a method for producing a commutator segment ring according to the preamble of the main claim. From DE-C2-25 09 107 a method is already known in which bevels are formed at the ends of a straight workpiece and the workpiece is formed into an annular blank with mutually opposite ends forming a gap. The blank is placed in a forming tool, aligned with one of the teeth of an inner punch forming the segment partial grooves, and formed into a commutator segment ring with a plurality of axial inner ribs forming commutator segments and a flange at one end. The inner ribs remain connected by narrow webs that curve outwards. The gap in the blank should run along a web. However, the method has the disadvantage that when the blank is formed into the commutator segment ring - for example by extrusion - the gap repeatedly runs out of the area of the straight web due to the relatively long path of the material and the high forming forces.

Aus der SU-A-10 41 023 ist lediglich ein Verfahren zum Herstellen eines Kommutators bekannt. Dabei wird bereits von einem geschlossenen Rohling (ohne Stoßfuge) mit hohlzylindrischem Schaft und einem Flansch an einem Ende des Schaftes ausgegangen. In den Rohling werden eine Vielzahl von Segmentteilnuten eingearbeitet, welche die dabei als axiale Innenrippen ausgebildeten Kommutatorsegmente in Umfangsrichtung. des Kommutatorsegmentringes begrenzen. Zugleich werden am Außenmantel des Rohlings Längsnuten ausgebildet. Beim nachfolgenden radialen Reduzieren des Kommutatorsegmentringes zum Verengen der Segmentteilnuten auf die gewünschte Breite werden die Stege zwischen den Längsnuten am Außenmantel und den Segmentteilnuten derart gebrochen, daß die Stege sich in die benachbarten Längsnuten schieben und so die Segmente durch Reibschweißen verbinden.From SU-A-10 41 023 only a method for manufacturing a commutator is known. A closed blank (without butt joint) with a hollow cylindrical shaft and a flange at one end of the shaft is already assumed. A large number of segment partial grooves are machined into the blank, and the commutator segments formed as axial inner ribs in the circumferential direction. limit the commutator segment ring. At the same time, longitudinal grooves are formed on the outer jacket of the blank. In the subsequent radial reduction of the commutator segment ring to narrow the segment partial grooves to the desired width, the webs between the longitudinal grooves on the outer jacket and the segment partial grooves are broken such that the webs slide into the adjacent longitudinal grooves and thus connect the segments by friction welding.

Aufgabe, Lösung und Vorteile der ErfindungObject, solution and advantages of the invention

Der Erfindung liegt die Aufgabe zugrunde, ein Verfahren zu schaffen, mit dem ein ringförmiger Rohling mit seinem sich über seine ganze Länge erstreckenden Spalt in eine Zwischenstufe mit hohlzylindrischem Schaft und Flansch abfallos kaltumgeformt werden kann, wobei der Spalt seinen Verlauf zur Längsachse der Zwischenstufe beibehält.The invention has for its object to provide a method with which an annular blank with its gap extending over its entire length can be cold formed waste-free into an intermediate stage with a hollow cylindrical shaft and flange, the gap maintaining its course to the longitudinal axis of the intermediate stage.

Zur Lösung der Aufgabe sind die im Hauptanspruch angegebenen Maßnahmen vorgesehen.The measures specified in the main claim are provided to achieve the object.

Dabei ist von Vorteil, daß der Rohling ohne eine Positioniernut bildende abgeschrägte Enden, welche einen Spalt einschließen, zunächst in eine Zwischenstufe mit hohlzylindrischem Schaft und Flansch an einem Ende umgeformt wird, wobei der Flansch bereits die Höhe und der Schaft etwa die Länge des späteren Kommutatorsegmentringes erhalten. Am Umformwerkzeug sind einfache Mittel vorgesehen, mit welchen eine Nut mindestens am Schaft der Zwischenstufe ausgebildet und der Werkstofffluß so geleitet wird, daß der Spalt der Zwischenstufe innerhalb der Nut in einer Ebene verläuft, welche sich radial durch die Längsachse der Zwischenstufe erstreckt. Dadurch ist gesichert, daß beim weiteren Umformen der Zwischenstufe in den Kommutatorsegmentring der Spalt nicht mehr aus seinem Verlauf parallel zur Längsachse abgelenkt werden kann und somit in dem ohnehin beim Trennen der Kommutatorsegmente zu entfernenden Steg verbleibt. Es werden keine ungleichmäßigen Kommutatorsegmente beiderseits des Spalts gebildet, die Standzeit des Werkzeugs wird verlängert und nur geringe Umformkräfte werden benötigt.It is advantageous that the blank is first formed into an intermediate stage with a hollow cylindrical shaft and flange at one end without a beveled ends forming a positioning groove, which enclose a gap, the flange already having the height and the shaft approximately the length of the later commutator segment ring receive. Simple means are provided on the forming tool, with which a groove is formed at least on the shaft of the intermediate stage and the material flow is guided in such a way that the gap of the intermediate stage runs within the groove in a plane which extends radially through the longitudinal axis of the intermediate stage. This ensures that when the intermediate stage is further shaped into the commutator segment ring, the gap can no longer be deflected from its course parallel to the longitudinal axis and thus remains in the web which is to be removed anyway when the commutator segments are separated. No uneven commutator segments are formed on both sides of the gap, the service life of the tool is extended and only low forming forces are required.

Durch die in den Unteransprüchen aufgeführten Maßnahmen sind vorteilhafte Weiterbildungen des im Hauptanspruch angegebenen Verfahrens möglich. Besonders vorteilhaft sind die zum Lenken des Werkstoffflusses vorgesehenen Mittel als eine Rippe an wenigstens einem Teil des Umformwerkzeugs auszubilden, mit welcher die Nut ausgebildet wird. Darüber hinaus können in vorteilhafter Weise an der Stirnseite des Flansches zusätzlich Verankerungsmittel für die späteren Kommutatorsegmente in der Isolierstoffnabe angeformt werden.Advantageous further developments of the method specified in the main claim are possible through the measures listed in the subclaims. The means provided for guiding the material flow are particularly advantageously designed as a rib on at least part of the forming tool with which the groove is formed. In addition, anchoring means for the later commutator segments can advantageously be integrally formed in the insulating material hub on the end face of the flange.

Zeichnungdrawing

Ausführungsbeispiele der Erfindung sind in der Zeichnung dargestellt und in der nachfolgenden Beschreibung näher erläutert. Es zeigen Figur 1 einen Werkstoffabschnitt und Figur 2 einen aus dem Werkstoffabschnitt gebogenen Rohling, jeweil in räumlicher Darstellung, Figuren 3 bis 10 eine Zwischenstufe mit Abwandlungen und Figur 11 ein Umformwerkzeug mit einer Zwischenstufe am Endes des Umformvorgangs, jeweils im Längsschnitt.Embodiments of the invention are shown in the drawing and explained in more detail in the following description. FIG. 1 shows a material section and FIG. 2 shows a blank bent from the material section, each in spatial representation, FIGS. 3 to 10 show an intermediate stage with modifications, and FIG. 11 shows a forming tool with an intermediate stage at the end of the forming process, in each case in longitudinal section.

Beschreibung der AusführungsbeispieleDescription of the embodiments

Ein gerader Werkstoffabschnitt 1 beispielsweise aus Kupfer ist zu einem hohlzylindrischen Rohling 2 gebogen. Die Enden des Werkstoffabschnitts liegen sich gegenüber und schließen einen Spalt in Form einer Stoßfuge 3 ein. Der Werkstoffabschnitt 1 kann rechteckigen oder runden Querschnitt haben.A straight material section 1, for example made of copper, is bent into a hollow cylindrical blank 2. The ends of the material section lie opposite each other and enclose a gap in the form of a butt joint 3. The material section 1 can have a rectangular or round cross section.

In einem Umformwerkzeug wird aus dem Rohling 2 eine Zwischenstufe 4 für einen Kommutatorsegmentring gebildet (Figuren 3 bis 10). Die Zwischenstufe 4 hat einen hülsenförmigen Schaft 5 und an einem Ende einen Flansch 6. Auch eine Zwischenstufe ohne Flansch oder eine scheibenförmige Zwischenstufe für einen Flachkommutatorsegmentring lassen sich mit einem entsprechend abgewandelten Umformwerkzeug aus dem « offenen Rohling 2 herstellen.An intermediate stage 4 for a commutator segment ring is formed from the blank 2 in a forming tool (FIGS. 3 to 10). The intermediate stage 4 has a sleeve-shaped shaft 5 and a flange 6 at one end An intermediate stage without a flange or a disc-shaped intermediate stage for a flat commutator segment ring can be produced from the “open blank 2” using a correspondingly modified forming tool.

Das Umformwerkzeug für Rückwärts-Hohlfließpressen (Figur 11) hat eine untere Stempelplatte 7 mit einer Matrize 8. In der Matrize 8 ist eine Bohrung 9 ausgebildet, welche in der unteren Stempelplatte 7 fortgesetzt ist und in welcher ein hohlstempelförmiger Auswerfer 10 bewegbar geführt ist. Der Auswerfer 10 sitzt beim Einlegen des Rohlings 2 und während des Umformens zur Zwischenstufe 4 auf dem Boden 11 der Bohrung 9 und ist durch einen Stößel 12 verschiebbar.The forming tool for backward hollow extrusion presses (FIG. 11) has a lower punch plate 7 with a die 8. A bore 9 is formed in the die 8, which is continued in the lower punch plate 7 and in which a hollow punch-shaped ejector 10 is movably guided. The ejector 10 sits when the blank 2 is inserted and during the forming to the intermediate stage 4 on the bottom 11 of the bore 9 and is displaceable by a plunger 12.

Der Auswerfer 10 ist mit einer Längsbohrung 13 versehen, in der ein Innenstempel 14 bewegbar aufgenommen ist. Der zylindrische Innenstempel 14 sitzt beim Einlegen des Rohlings 2 ebenfalls auf dem Boden 11 der Bohrung 9 und ist mit einem hubbegrenzenden Anschlag 15 versehen.The ejector 10 is provided with a longitudinal bore 13 in which an inner punch 14 is movably received. The cylindrical inner punch 14 also sits on the bottom 11 of the bore 9 when the blank 2 is inserted and is provided with a stroke-limiting stop 15.

In einer Stempelplatte 16 des Umformwerkzeugs ist ein Umformstempel 17 fest angeordnet und mit der Stempelplatte 16 bewegbar. Der Umformstempel 17 hat einen hülsenförmigen Endabschnitt 18, welcher als Fließpreßstempel in die Matrize 8 bewegbar ist. In einer Längsbohrung 19 des Umformstempels 17 ist ein Gegenstempel 20 längsbewegbar geführt und durch einen in der oberen Stempelplatte 16 bewegbar angeordneten Stempel 21 gegenüber dem Umformstempel 17 und der oberen Stempelplatte 16 auf die untere Stempelplatte 7 zu bewegbar. Der Gegenstempel 20 dient als Gegenhaltung am Ende des Schaftes 5 der zu formenden Zwischenstufe 4. Dabei ermöglichst der Gegenstempel 20 durch seinen hohlzylindrischen Endabschnitt 22 das volle Ausbilden des Querschnitts der Zwischenstufe 4 am Ende des Schaftes 5, weil sein Innendurchmesser etwas größer ausgebildet sein kann als der Außendurchmesser des Innenstempels 14 und das Entweichen einer geringen Menge Werkstoffs in den Ringspalt zwischen den Stempeln 20 und 14 erlaubt. Außerdem kann der Gegenstempel 20 als Zusätzlicher Auswerfer dienen, falls die zwischenstufe 4 am Umformstempel 17, 18 hängenbleiben sollte. Im Gegenstempel 20 ist noch ein Stößel 23 in Form einer Schraube angeordnet, mit der die Endlage des Gegenstempels 20 in Umformstempel 17 und oberer Stempelplatte 16 einstellbar ist. Der Stößelkopf dient obendrein noch als oberer Anschlag zum Begrenzen der Bewegung des Innenstempels 14.A forming stamp 17 is fixedly arranged in a stamping plate 16 of the forming tool and can be moved with the stamping plate 16. The forming die 17 has a sleeve-shaped end section 18 which can be moved into the die 8 as an extrusion die. In a longitudinal bore 19 of the forming die 17, a counter-punch 20 is guided so as to be longitudinally movable and can be moved towards the lower die plate 7 relative to the shaping die 17 and the upper die plate 16 by a die 21 movably arranged in the upper die plate 16. The counter-punch 20 serves as a counterhold at the end of the shaft 5 of the intermediate stage 4. The counter-stamp 20 enables the cross-section of the intermediate stage 4 to be fully formed at the end of the shaft 5 through its hollow cylindrical end section 22, because its inside diameter can be somewhat larger than the outer diameter of the inner die 14 and the escape of a small amount of material into the annular gap between the dies 20 and 14. In addition, the counter stamp 20 can serve as an additional ejector if the intermediate stage 4 should get caught on the forming stamp 17, 18. In the counter-punch 20 there is also a plunger 23 in the form of a screw with which the end position of the counter-punch 20 in the forming die 17 and the upper die plate 16 can be adjusted. The plunger head also serves as an upper stop to limit the movement of the inner punch 14.

Beim Umformen des Rohlings 2 in die Zwischenstufe 4 muß die Stoßfuge 3 als gerader Spalt erhalten bleiben, der parallel zur Längsachse der Zwischenstufe 4 in einer sich radial durch die Längsachse erstreckenden Ebene verläuft. Nur dann läßt sich in einem nachfolgenden an sich bekannten und nicht näher dargestellten Verfahren aus der Zwischenstufe 4 ein Kommutatorring formen, bei dem der Spalt nur in einer Segmentteilnut läuft und nicht in die angrenzenden Segmente ausweicht. Am Umformwerkzeug sind daher einfache den Werkstofffluß während des Umformens des Rohlings 2 in die Zwischenstufe 4 lenkende Mittel vorgesehen. Sie bilden zumindest am Schaft 5 der Zwischenstufe 4 eine Nut, in der der Spalt verläuft. Mehrere Ausführungsbeispiele und Abwandlungen sind im folgenden beschrieben.When shaping the blank 2 into the intermediate stage 4, the butt joint 3 must be maintained as a straight gap which runs parallel to the longitudinal axis of the intermediate stage 4 in a plane extending radially through the longitudinal axis. Only then can a commutator ring be formed from the intermediate stage 4 in a subsequent method known per se and not shown in detail, in which the gap runs only in one segment partial groove and does not escape into the adjacent segments. Simple means are therefore provided on the forming tool to direct the material flow during the forming of the blank 2 into the intermediate stage 4. At least on the shaft 5 of the intermediate stage 4, they form a groove in which the gap runs. Several embodiments and modifications are described below.

Im Ausführungsbeispiel nach Figur 3 ist in der Zwischenstufe 4 eine Längsnut 24 im Innenmantel 25 ausgebildet, in der der Spalt 3 verläuft. Der Innenstempel 14 des Umwerkzeugs hat dazu am Mantel eine Längsrippe 26. Der Auswerfer 10 und der Gegenstempel 20 sind mit einer entsprechenden Längsnut 27 bzw. 28 versehen.In the exemplary embodiment according to FIG. 3, in the intermediate stage 4, a longitudinal groove 24 is formed in the inner jacket 25, in which the gap 3 runs. For this purpose, the inner punch 14 of the tool has a longitudinal rib 26 on the jacket. The ejector 10 and the counter punch 20 are provided with a corresponding longitudinal groove 27 and 28, respectively.

Bei der abgewandelten Zwischenstufe 4 nach Figur 4 ist die Längsnut 24 in einer Radialnut 29 an der Stirnseite 30 des Flansches 6 fortgesetzt. Dazu ist der Auswerfer 10 an seiner Stirnseite mit einer Radialrippe 31 versehen, welche in derselben radialen Ebene durch die Längsachse der Zwischenstufe 4 und somit des Umformwerkzeugs verläuft wie die Längsrippe 26 des Innenstempels 14. Der Spalt 3 im Flansch 6 verläuft somit in der Radialnut 29.In the modified intermediate stage 4 according to FIG. 4, the longitudinal groove 24 is continued in a radial groove 29 on the end face 30 of the flange 6. For this purpose, the ejector 10 is provided on its end face with a radial rib 31 which runs in the same radial plane through the longitudinal axis of the intermediate stage 4 and thus of the forming tool as the longitudinal rib 26 of the inner punch 14. The gap 3 in the flange 6 thus runs in the radial groove 29 .

In einem zweiten Ausführungsbeispiel nach Figur 5 ist in der Zwischenstufe 4 eine Längsnut 32 an deren Außenmantel 33 ausgebildet. Der Endabschnitt 18 des Umformstempels 17 ist dazu mit einer Längsrippe 34 versehen. Dementsprechend ist im Gegenstempel 20 eine Längsnut 35 vorgesehen.In a second exemplary embodiment according to FIG. 5, a longitudinal groove 32 is formed on the outer jacket 33 in the intermediate stage 4. To this end, the end section 18 of the forming die 17 is provided with a longitudinal rib 34. Accordingly, a longitudinal groove 35 is provided in the counter-punch 20.

Bei der abgewandelten Zwischenstufe nach Figur 6 ist die Längsnut 32 in einer Radialnut 36 an der Rückseite 37 des Flansches 6 fortgesetzt, in der der Spalt 3 im Flansch 6 verläuft. Der Endabschnitt 18 des Umformstempels 17 ist zum Herstellen der radialen Fortsetzung 36 der Längsnut 32 an seiner Stirnseite mit einer radial an die Längsrippe 34 anschließenden Rippe 38 versehen.In the modified intermediate stage according to FIG. 6, the longitudinal groove 32 is continued in a radial groove 36 on the rear side 37 of the flange 6, in which the gap 3 runs in the flange 6. To produce the radial continuation 36 of the longitudinal groove 32, the end section 18 of the forming die 17 is provided on its end face with a rib 38 which adjoins the longitudinal rib 34 radially.

In einer abgewandelten Zwischenstufe 4 nach Figur 7 sind je eine Längsnut 24 und 32 am Schaft ausgebildet. Das Umformwerkzeug ist dazu mit dem Innenstempel 14 mit Längsrippe 26 und dem Umformstempel 17, 18 mit Längsrippe 34 ausgerüstet.In a modified intermediate stage 4 according to FIG. 7, a longitudinal groove 24 and 32 are formed on the shaft. For this purpose, the shaping tool is equipped with the inner punch 14 with a longitudinal rib 26 and the shaping punch 17, 18 with a longitudinal rib 34.

In einer weiteren abgewandelten Zwischenstufe 4 nach Figur sind die Nuten 24, 29 und 32, 36 kombiniert ausgebildet. Auch andere Kombinationen der Nuten sind möglich.In a further modified intermediate stage 4 according to the figure, the grooves 24, 29 and 32, 36 are formed in combination. Other combinations of the grooves are also possible.

Bei einem dritten Ausführungsbeispiel nach Figur 9 ist die Zwischenstufe 4 mit einer Ringnut 39 an der Stirnseite 30 des Flansches 6 versehen. Der Auswerfer 10 des Umformwerkzeugs ist zum Formen der Ringnut 39 mit einem entsprechend ringförmigen Vorsprung 40 an seiner Stirnseite versehen.In a third exemplary embodiment according to FIG. 9, the intermediate stage 4 is provided with an annular groove 39 on the end face 30 of the flange 6. The ejector 10 of the forming tool is provided with a corresponding annular projection 40 on its end face for shaping the annular groove 39.

Eine Abwandlung der Zwischenstufe 4 nach Figur 9 ist in Figur 10 dargestellt. An der Stirnseite 30 des Flansches 6 ist ein ringförmiger Fortsatz 41 ausgebildet. Der Auswerfer 10 des Umformwerkzeugs ist zum Herstellen des Fortsatzes 41 mit einem erweiterten Endabschnitt 42 der Längsbohrung 13 versehen.A modification of the intermediate stage 4 according to FIG. 9 is shown in FIG. 10. An annular extension 41 is formed on the end face 30 of the flange 6. The ejector 10 of the forming tool is provided with an enlarged end section 42 of the longitudinal bore 13 for producing the extension 41.

Die Ringnut 39 und der Fortsatz 41 bilden bereits an der Zwischenstufe 4 angeformte zusätzliche Verankerungsmittel der Segmente, die aus einem in einem nachfolgenden Verfahren herzustellenden Kommutatorsegmentring hervorgehen. Eine Isolierstoffnabe, in welcher die Segmente des Kommutators verankert werden, liegt mit einem Bund an der Stirnseite 30 der späteren Segmente und greift klammernd in die Ringnut 39 oder um den Fortsatz 41.The annular groove 39 and the extension 41 already form additional anchoring means of the segments formed on the intermediate stage 4 emerge from a commutator segment ring to be produced in a subsequent method. An insulating material hub, in which the segments of the commutator are anchored, lies with a collar on the end face 30 of the later segments and engages with a clamp in the annular groove 39 or around the extension 41.

Zum Herstellen der verschiedenen Ausführungsbeispiele und Abwandlungen der Zwischenstufe 4 wird der Rohling 2 in das geöffnete Umformwerkzeug eingelegt und ausgerichtet. Beim geöffneten Werkzeug ist die obere Stempelplatte 16 mit dem Umformstempel 17 und dem Gegenstempel 20 von der unteren Stempelplatte 7 mit Matrize 8, Auswerfer 10 und Innenstempel 14 abgehoben, so daß der Endabschnitt 18 des Umformstempels 17 in ausreichender Höhe über der Oberseite, das ist die Aufnahmefläche 43 der Matrize 8, steht. Die Stirnseiten von Umformstempel 17, 18 und Gegenstempel 20 liegen dabei in einer Ebene. Der Innenstempel 14 und der Auswerfer 10 stehen auf dem Boden 11 der Bohrung 9 in Matrize 8 und unterer Stempelplatte 7. Der Rohling 2 wird über den Innenstempel 14 auf den Auswerfer 10 geschoben, wobei die Stoßfuge 3 den Rohling 2 an der Längsrippe 26 des Innenstempels 14 ausrichtet. Bei Zwischenstufen 4 mit Längsnut am Außenmantel (Figuren 5 und 6) sind an sich bekannte und nicht näher dargestellte Ausrichtmittel vorgesehen.In order to produce the various exemplary embodiments and modifications of the intermediate stage 4, the blank 2 is inserted into the opened forming tool and aligned. When the tool is open, the upper stamp plate 16 with the forming stamp 17 and the counter stamp 20 is lifted off the lower stamp plate 7 with the die 8, ejector 10 and inner stamp 14, so that the end section 18 of the forming stamp 17 is at a sufficient height above the top, that is Receiving surface 43 of the die 8 stands. The end faces of the forming die 17, 18 and counter-die 20 lie in one plane. The inner die 14 and the ejector 10 are on the bottom 11 of the bore 9 in the die 8 and the lower die plate 7. The blank 2 is pushed over the inner die 14 onto the ejector 10, the butt joint 3 the blank 2 on the longitudinal rib 26 of the inner die 14 aligns. In the case of intermediate stages 4 with a longitudinal groove on the outer jacket (FIGS. 5 and 6), alignment means known per se and not shown in detail are provided.

Die obere Stempelplatte 16 wird nunmehr gesenkt, bis der Endabschnitt 18 des Umformstempels 17 mit dem Gegenstempel 20 auf dem Rohling 2 aufliegt. Der Umformstempel 17, 18 wird dann auf den Rohling 2 gepreßt, so daß durch Rückwärts-Hohlfließpressen die Zwischenstufe 4 gebildet wird. Der Umformstempel 17, 18 bildet dabei den Flansch 6 in der Höhe des aus der Zwischenstufe 4 später in an sich bekannter Weise herzustellenden Kommutatorsegmentringes aus. Der in den von Innenstempel 14, Endabschnitt 18 und Gegenstempel 20 umschlossenen hohlzylindrischen Raum ausweichende Werkstoff des Rohlings 2 wird in den Schaft 5 umgeformt. Dabei wird die Länge des Schaftes 5 durch den unter dem Einfluß einer auf den Stempel 21 wirkenden Gegenkraft stehende Gegenstempel 20 bestimmt. Der in dem Auswerfer 10 frei bewegbare Innenstempel 14 wird beim Ausbilden des Schaftes 5 durch die zwischen Innenstempel 14 und Schaft 5 auftretenden Reibkräfte in den Schaft 5 und somit in den Unformstempel 17, 18 mitgenommen und bildet mit seiner Längsrippe 26 die Längsnut 24 aus. Durch die Längsrippe 26 wird der Werkstofffluß so gelenkt, daß die Stoßfuge 3 zu einem geraden Spalt ausgedehnt wird, welcher in der Längsnut 24 parallel zur Längsachse der Zwischenstufe 4 in einer sich radial durch die Längsachse erstreckenden Ebene verläuft (Figur 11 mit Zwischenstufe 4 nach Figur3).The upper stamp plate 16 is now lowered until the end section 18 of the forming stamp 17 with the counter-stamp 20 rests on the blank 2. The forming die 17, 18 is then pressed onto the blank 2, so that the intermediate stage 4 is formed by backward hollow extrusion. The forming die 17, 18 forms the flange 6 at the level of the commutator segment ring to be produced later from the intermediate stage 4 in a manner known per se. The material of the blank 2 which escapes into the hollow-cylindrical space enclosed by the inner punch 14, end section 18 and counter-punch 20 is shaped into the shaft 5. The length of the shaft 5 is determined by the counter-stamp 20, which is under the influence of a counterforce acting on the stamp 21. The inner ram 14, which is freely movable in the ejector 10, is entrained in the shaft 5 and thus in the shaping rams 17, 18 when the shaft 5 is formed by the friction forces occurring between the inner ram 14 and the shaft 5, and forms the longitudinal groove 24 with its longitudinal rib 26. The material flow is guided by the longitudinal rib 26 in such a way that the butt joint 3 is expanded to form a straight gap which runs in the longitudinal groove 24 parallel to the longitudinal axis of the intermediate step 4 in a plane extending radially through the longitudinal axis (FIG. 11 with intermediate step 4 according to FIG. 3) ).

Zum Auswerfen der Zwischenstufe 4 wird die obere Stempelplatte 16 mit dem Umformstempel 17, 18 in die Ausgangsstellung zurückbewegt. Der Auswerfer 10 schiebt die Zwischenstufe 4 vom Innenstempel 14, der in seine Ausgangsstellung auf dem Boden 11 der Bohrung 9 zurückkehrt und aus der Matrize 8. Sollte die Zwischenstufe 4 im Umformstempel 17, 18 hängenbleiben, wirkt der Gegenstempel 20 als zusätzlicher Auswerfer, ehe er in seine Ausgangsstellung zurückbewegt wird. Nach dem Auswerfen kehrt der Auswerfer 10 ebenfalls in seine Ausgangsstellung zurück.To eject the intermediate stage 4, the upper stamp plate 16 with the forming stamp 17, 18 is moved back into the starting position. The ejector 10 pushes the intermediate stage 4 from the inner die 14, which returns to its initial position on the bottom 11 of the bore 9 and out of the die 8. If the intermediate stage 4 gets caught in the forming die 17, 18, the counter-die 20 acts as an additional ejector before it is moved back to its original position. After ejection, the ejector 10 also returns to its starting position.

Claims (9)

1. Process for the production of an intermediate stage (4) for a commutator segment ring with a plurality of axial inner ribs and a flange at one end by means of forming of an annular blank (2) of a straight section of material (1) with ends running perpendicular to its longitudinal axis and longitudinal sides running parallel to said axis, in which the ends of the section of material (1) are opposite each other in the circumferential direction of the blank (2) and enclose a gap (3) of the same cross-section over the length of the gap, characterized in that the blank (2) received in a forming die is formed by means of moulding punches (14 ; 17, 18) into the intermediate stage (4) with a hollow-cylindrical shank (5), the means (26; 34) directing the material flow during the forming parallel to the longitudinal axis of the intermediate stage (4) developing a groove (24 ; 32) at least on the shank (5), the centre line of which groove extends in forming direction in a plane leading radially through the longitudinal axis of the intermediate stage (4), and in which groove (24; 32) the gap (3) runs.
2. Process according to claim 1, characterized in that the blank (2) placed in a workpiece holder of the forming die is pressed by a ring punch (17, 18), forming the flange (6), to the thickness of the flange of the commutator segment ring, the displaced material of the blank (2) escaping into the hollow-cylindrical space forming the shank (5), which space is enclosed by the inner wall of the ring punch (18), the shell of a cylindrical inner punch (14), having means (26) for directing the material flow during forming, and a counter-punch (10) limiting the length of the shank (5).
3. Process according to Claims 1 and 2, characterized in that the means directing the material flow parallel to the longitudinal axis of the intermediate stage (4) during forming are designed as a rib (26) radially projecting from the shell of the cylindrical inner punch (14) and running parallel to the longitudinal axis of the latter.
4. Process according to Claims 1 and 2, characterized in that the means (26, 31) directing the material flow parallel to the longitudinal axis of the intermediate stage (4) during forming are designed as a rib (26) radially projecting from the shell of the cylindrical inner punch (14) and running parallel to the longitudinal axis of the intermediate stage (4) and an additional rib (31) extending in the same radial plane relative to the longitudinal axis, on a part (10) of the forming die lying against the face of the flange (6).
5. Process according to claim 1, characterized in that the blank (2) placed in a workpiece holder of the forming die is pressed by a ring punch (17, 18), forming the flange (6), to the thickness of the flange of the commutator segment ring, the displaced material of the blank (2) escaping into the hollow-cylindrical space forming the shank (5), which space is enclosed by an inner wall of the ring punch (17, 18), having the means (34) directing the material flow during forming, the shell of a cylindrical inner punch (14) and a counter-punch (10) limiting the length of the shank (5).
6. Process according to Claims 1 and 5, characterized in that the means directing the material flow parallel to the longitudinal axis of the intermediate stage (4) during forming are designed as a rib (34) projecting radially from the inner wall of the ring punch (17, 18) and running parallel to the longitudinal axis of the latter.
7. Process according to Claims 1 and 5, characterized in that the means directing the material flow parallel to the longitudinal axis of the intermediate stage (4) during forming are designed as a rib (34) projecting radially from the inner wall of the ring punch (17,18) and running parallel to the longitudinal axis of the intermediate stage (4) and an additional rib (38) adjoining the face of the ring punch (17, 18) in the same radial plane.
8. Process according to Claim 1, characterized in that the blank (2) placed in a workpiece holder of the forming die is pressed by a ring punch (17, 18), forming the flange (6), to the thickness of the flange of the commutator segment ring, the displaced material of the blank (2) escaping into the hollow-cylindrical space forming the shank (5), which space is enclosed by the inner wall of the ring punch (17, 18) and the shell of an inner punch (14), both of which punches (14 ; 17, 18) have means (26; 34) for directing the material flow parallel ot the longitudinal axis of the intermediate stage (4) during forming, and a counter-punch (10) limiting the length of the shank (5).
9. Process according to Claim 1, characterized in that the blank (2) placed in a workpiece holder of the forming die is pressed by a ring punch (17, 18), forming the flange (6), to the thickness of the flange of the commutator segment ring, the displaced material of the blank (2) escaping into the hollow-cylindrical space forming the shank (5), which space is enclosed by the inner wall of the ring punch (17, 18) and the shell of an inner punch (14), at least one of which punches (17, 18 ; 14) has means for directing the material flow parallel to the longitudinal axis of the intermediate stage (4) during forming and is enclosed by a counter-punch (10) limiting the length of the shank (5), and a concentric anchoring ring being formed by means on a part (10) of the forming die at the face of the flange (6) of the intermediate stage (4).
EP84109726A 1983-09-15 1984-08-16 Method of manufacturing an intermediate stage for a commutator-segment collar Expired EP0137957B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE19833333335 DE3333335A1 (en) 1983-09-15 1983-09-15 METHOD FOR PRODUCING AN INTERMEDIATE FOR A COMMUTATOR SEGMENT RING
DE3333335 1983-09-15

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EP0137957A1 EP0137957A1 (en) 1985-04-24
EP0137957B1 true EP0137957B1 (en) 1987-07-29

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EP (1) EP0137957B1 (en)
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FR2585521B1 (en) * 1985-07-26 1987-11-20 Bruss Respub Nauc METHOD FOR MANUFACTURING ELECTRIC MACHINE COLLECTORS AND COLLECTORS OBTAINED BY SAID METHOD
DE19681590T1 (en) * 1996-08-05 1998-08-20 Kanemitsu Akashi Kk Method of forming a cylindrical part of a sheet metal member with a central opening
US6242839B1 (en) 2000-03-01 2001-06-05 Kirkwood Industries, Inc. Commutator and method for manufacturing
DE10107109C2 (en) * 2001-02-14 2003-07-24 Federal Mogul Wiesbaden Gmbh Collar bushing, process for its manufacture and bending tool for the production of coils on a bushing
CN100418693C (en) * 2005-12-20 2008-09-17 浙江长城换向器有限公司 Cold xtrusion manufacturing method of cylindrical commutator
DE102006020861B4 (en) * 2006-05-04 2010-08-26 Gesenkschmiede Schneider Gmbh Single-stage forging process and device for the production of bush-type forgings
CN106734594A (en) * 2015-11-24 2017-05-31 宁波胜克换向器有限公司 A kind of compacting tool set for the commutator hook pin that bends

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DE2509107C2 (en) * 1974-03-13 1984-12-06 Nippondenso Co., Ltd., Kariya, Aichi Method of manufacturing a commutator

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FR2185945A5 (en) * 1972-05-23 1974-01-04 Peugeot & Renault
JPS55141348A (en) * 1979-04-19 1980-11-05 Mitsubishi Steel Mfg Co Ltd Production of product having tooth profile and its apparatus
SU874255A1 (en) * 1979-05-11 1981-10-23 Краматорский Индустриальный Институт Method of shaping hollow articles with flange
YU81780A (en) * 1980-03-24 1982-10-31 Kolektor Method of producing a cast in commutator
DE3203438A1 (en) * 1982-02-02 1983-08-11 Motomak Motorenbau, Maschinen- u. Werkzeugfabrik, Konstruktionen GmbH, 8070 Ingolstadt METHOD FOR PRODUCING A METAL SLEEVE FROM A CYLINDRICAL PIPE SECTION

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DE2509107C2 (en) * 1974-03-13 1984-12-06 Nippondenso Co., Ltd., Kariya, Aichi Method of manufacturing a commutator

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US4621514A (en) 1986-11-11
DE3465029D1 (en) 1987-09-03
JPS6087947A (en) 1985-05-17
EP0137957A1 (en) 1985-04-24
DE3333335A1 (en) 1985-03-28

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