May 29, 2012
Schuler has developed new techniques for producing automatic transmission components with advanced in-die processes such as spline forming with in-die rollers; roll forming with smaller in-die rollers; and segment forming for tall, thin components.
The spline forming technology involves the rolling of disc carriers with thin and heavy materials to be formed using the in-die process. According to the company, these process improvements allow manufacturers to achieve a consistent dimensional accuracy for wall thickness, piston pockets, and major and minor diameters. The system reduces part stress, minimizes material thinout from end-to-end of the spline, and improves surface hardness by 25 to 30 percent with runout tolerances of ± 0.006 in.
The patented, smaller in-die roller process is designed for components that require high centrifugal forces. The proprietary process offers shorter process time because it draws and rolls in one die using smaller rollers and a special bearing design. Using this technology, components can be partially rolled using smaller rollers, and the spline can be rolled close to the reinforcement ring. By combining the draw and roll station, the process allows the part to be formed in fewer stations.
The patented segment forming process allows taller components with thin initial sheet thickness to be spline-rolled without material thinning. In this process, parts can be rolled over the full length, allowing for reinforcement rings in the middle and tapered lead-ins to ease clutch plate assembly.