DESC:Field of the invention:
Present invention generally discloses a process for manufacturing Claw Pole, particularly to be used in alternators, wherein the said process involves continuous two-step forging operations at higher temperature zone towards creating the basic structural features therein.
Back Ground of the invention:
Claw Pole is a part of alternator, which is an essential component in every motor vehicle. Said Claw Pole generates a desired amperage of electric current, when an assembly rotates and such electricity is utilized for various purposes in the vehicle, namely for lighting, starting the vehicle, charging the battery etc. The Claw Pole assembly is chosen in some specific standard and very compact dimensions towards mutually accommodating each other in the alternator therein. Therefore the selection of material and its processing, and standardization of size and dimension of the Claw Pole components become important so that they deliver desired amperage at desired speeds or RPM.
Conventionally such Claw Pole components are manufactured involving several steps of forging, followed by other mechanical operations; wherein the basic structure of the Claw Pole is created in forging and machining, particularly involving at least three stage forging operations at specific temperature-pressure condition.
Said conventional three-step forging operations at higher temperature zones (warm or hot), as depicted in Figure 1, are performed preferably at three station press with open die-punch arrangements therein, wherein the ingot undergoes upsetting, followed by forging to obtain a pre-formed work-piece, which finally gets forged in the final Claw Pole component in next step. After completion of such three-step forging operations, the finally obtained forged component is subjected to trimming, sizing, central-hole punching, and other machining operations. While performing all such operations, almost every step of forging creates flash and therefore substantial amount of wastage is obtained. Due to creation of such wastage, it is not possible to achieve uniform desired strength in each Claw Pole component formed in continuation. Further such forging scheme attracts more machining operations and therefore yield of finished product per unit time is reduced. Such manufacturing process is more resource consuming, creates large quantity of wastage of material and also involves more time, energy and man power.
The invention already proposed herein is intended to design a novel process for large scale manufacturing of Claw Pole components with effective functional and structural features and enhanced durability, wherein such process involves minimum resources, tools and machinery, energy, time and man power and which releases reduced quantity of wastage therein. The proposed process herein is more cost effective in comparison to conventional manufacturing of Claw Pole components, supports quick and large scale production, and thus enhances its value in industrial application.
The prime object of the invention is to propose a new and advanced process for manufacturing Claw Pole component, wherein said process involves two-step forging operations at higher temperature (that is in hot and warm conditions), followed by trimming and cold sizing and further followed by stepwise machining operations.
The another object is to propose a process for manufacturing Claw Pole, wherein the basic structure of said Claw Pole is created in two-step forging operations, and wherein said basic structure is further refined and finished in follow-up operations.
Yet another object is to propose a process for manufacturing Claw Pole, wherein said two-step forging operations are performed by two optional routes, wherein in first route the heated billet is forged towards upsetting and in next forging step final basic structure of the Claw Pole component is formed; wherein in another optional route the billet is forged in hot or warm condition to obtain a preformed work piece and in next hot forging step the final basic structure of Claw Pole component, same as in first optional route herein, is obtained.
Yet another object of the invention is to propose two alternate and optional routes for carrying out the proposed two-step forging, wherein the intermediate embodiments formed in said two routes are different, but the final Claw Pole component formed possesses same basic structural features, irrespective of substantially different intermediate embodiments formed during first step forging in said two optional routes.
Yet another object of the invention is to propose a process for manufacturing Claw Pole involving two-steps forging, wherein said manufacturing process is characterized in producing lesser flash or material wastage.
Yet another object of the invention is to propose a process for manufacturing Claw Pole involving two-steps forging, wherein said manufacturing process is characterized in involving lesser resources, machinery, tools, energy and man-power.
Summary of the invention:
The invention generally discloses a process for manufacturing Claw Pole by involving hot or warm forging at two continuous steps, and after completing the forging operations trimming and cold sizing steps are performed, followed by certain machining steps towards finalizing the Claw Pole product.
For performing two-step forging on the billet, the present disclosure proposes two optional routes, which are different from each other due to creating different intermediate work pieces during first step forging, wherein said intermediate work-pieces are completely different in terms of their structure, shape and dimension. However, when said intermediate work-piece, created in any of the two proposed route, undergoes second forging operation then the same final structure of the Claw Pole component with desired number of legs and hub is achieved. Such final structure of the Claw Pole is achieved irrespective of the structure, shape and dimension of the intermediate work-piece obtained in the first forging operation and undergoing the second step forging. Though these two-step continuous forging operations, in both the proposed optional forging routes, are performed on vertical press with open punch-die arrangements, the quantity of flash generated is very less in comparison to conventional three-step forging.
Basic Claw Pole component, obtained after two-step forging operations, is subjected to trimming, preferably warm trimming just after the forging operation in continuation. Such trimming removes the flash from the basic body of the Claw Pole. Subsequently the trimmed body of the Claw Pole is subjected to sizing, preferably in cold condition so that best possible hardness, and structural strength and enhanced functional life of the final product can be achieved. After sizing, the Claw Pole component is subjected to required machining, mainly central hole drilling, CNC machining etc.
For the proposed process herein forging press with two press stations is chosen, wherein said two press stations are provisioned with open Punch and Die arrangement in vertical position. Such two station forging press is the best suitable for performing the proposed process of Claw Pole making in forging, mainly due to customized designing of Punch-Die arrangement, substantially less cost involvement in machinery and other resources and sufficiently high production rate. The Claw Pole formed in the proposed process are of high strength and very effective in their prolonged functionality.
The invention, as already proposed herein is substantially illustrated with the help of certain schematic drawings and manufacturing schemes herein below.
Detailed Description of the invention:
Figure 1: It represents prior known schematic scheme of three-step forging, towards creating claw Pole component.
Figure 2: It represents schematic scheme of one optional route to perform two-step forging for creating Claw Pole component, wherein at first step upset forging is the performed at hot condition.
Figure 3: It represents schematic scheme of another optional route to perform two-step forging for creating Claw Pole component, wherein at first step Pre-forming is performed on the billet at warm condition.
Figure 4: It represents one schematic view of the Punch and Die arrangement, while performing the upsetting on the billet in hot condition as first forging operation of one of the proposed optional forging routes;
Figure 5: It represents one schematic view of the Punch and Die arrangement, while performing the Pre-forging forging operation, preferably the warm forging, on the billet to form the intermediate work-piece through the another proposed optional forging route ;
Figure 6: It represents one schematic view of the Punch and Die arrangement, while performing the second step forging operation on any of the optionally obtained intermediate work-piece, to form the final Claw Pole component of same structure, shape and dimension.
In common known practice, as shown in Figure 1, the billet (1) is subjected to three-step forging, preferably at higher temperature. Preferably such three-step forgings are performed as warm forging at temperature in the range of 8500C to 9000C and for such forging operations open punch-die arrangement is chosen in vertical position. The billet (1) is subjected to stepwise forging operations and forms upsetted work-piece (2a), pre-formed work-piece (3a) and then final Claw Pole component 4(a). All the forged products (2a), (3a) and (4a) are created with some flash, wherein the final product consists of substantially high amount of flash. After completion of forging operations, the forged component (4a) undergoes trimming and thus the final Claw Pole product (5a) is formed after separating from the flash (6a).
To reduce the number of steps of conventional forging towards Claw Pole making, two-step forging is suggested herein and such two-step forging is depicted in two optional schemes of Figure 2 and 3.
As per figure 2, the billet (1) is heated in the range of 9000C to 12500C. The heated billet (1) undergoes vertical upsetting and forms the intermediate work-piece (2) and then it is transferred to another vertical press station with open punch-die arrangement for second step forging. After receiving the second step forging, the Claw Pole component (3) is obtained, which is associated with certain quantity of flash. Thus the billet (1) is forged as Claw Pole with flash (3) through making intermediate work-piece (2) by upsetting.
As per Figure 3, the billet (1) is heated in the range of 9000C to 12500C. Preferably, the biller (1) is heated in the range of 10000C to 11500Cand it is then subjected to first forging operation, which is a forming operation towards creating a Pre-formed work-piece (6) as the intermediate work-piece. The intermediate work-piece (6), in continuation, is further subjected to next step of forging at the vertical press, preferably with open punch-die arrangement. After receiving the second forging operation, the intermediate work-piece (6) gets transformed into the final Claw Pole component (3) with certain flash content. Thus the billet (1) is forged as Claw Pole with flash (3) through making intermediate work-piece (6) by pre-forming.
After completion of said two-step forging, in any of the optional two routes, the Claw Pole component (3) with flash content is subjected to the trimming press where it receives trimming operation, preferably in warm condition, and thus the final structure (4) of the Claw Pole is achieved. The flash content (5) gets removes while trimming. The proposed two-step forging operations, in both the proposed optional routes, are so designed that it creates substantially lesser quantity of flash in comparison to conventional three-step such forging for Claw Pole making.
The Claw Pole (4) is then conditioned for cold sizing operation, followed by mechanical steps, mainly central hole drilling. Sizing in cold condition enhances the metal grain density and the hardness/strength of the component.
While performing upset forging (Figure 4) in one optional route for Claw Pole making, as schematically shown in Figure 2, open Punch (7) and Die (8) arrangement is preferred in the vertical press, so that the intermediate work-piece (2) occupies the space (2’) between (7) and (8). The Punch and Die arrangement is so customized and the billet (1) is so heated and conditioned that almost no flash is formed during upsetting.
While performing first step forging towards pre-forming (Figure 5) in one optional route for Claw Pole making, as schematically shown in Figure 3, the open Punch (11) and Die (12) arrangement is preferred in vertical press, so that the intermediate work-piece (6) occupies the space (6’) between (11) and (12). The Punch and Die arrangement is so customized and the billet (1) is so heated and conditioned that insignificant amount of flash gets generated while forming.
While performing the second step forging (Figure 6) towards making the final structure of the Claw Pole component, the forging press is preferably chosen with open Punch (9) and Die (10) arrangement. After receiving the forging thrust, the intermediate work-piece (2) or (6) obtained in any of the proposed optional route here, gets perfectly occupied in the cavity 4’ and thus the final Claw Pole component (3) with flash content gets formed. During the second step forging operation certain flash gets created with the body of the desired Claw Pole component, which requires trimming operation to remove.
Scope of the present invention:
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. It is therefore contemplated that such modifications can be made without departing from the spirit or scope of the present invention as defined.

,CLAIMS:1. Process for manufacturing Claw Pole, wherein the said process involves continuous two-step forging operations at higher temperature zone towards creating the basic Claw Pole structural, wherein said process is characterized in the first step forging of the billet (1) at higher temperature in the range 9000C to 12000C and optionally forming the intermediate work-piece (2) or (6), followed by further forging the said intermediate work-piece (2) or (6) to create the complete structure (3) of the Claw Pole, with flash;
and wherein the said process is further characterized in trimming operation in worm condition of the forged Claw Pole component (3) with flash towards removing the flash (5) from the final Claw Pole structure (4), which is further subjected to cold sizing and other machining operations.
2. Process for manufacturing Claw Pole involves continuous two-step forging operations, as claimed in claim 1, wherein said two-step warm or hot forging operation is performed by optionally creating either an intermediate work-piece (2) or another intermediate work-piece (6); followed by forming the final Claw Pole structure (3) at second step forging; wherein said optionally created intermediate work-pieces (2) and (6) are completely different from each other in terms of structure, shape and dimension.
3. Process for manufacturing Claw Pole involves continuous two-step forging operations, as claimed in claim 1, wherein two optional routes to perform said two-step forging is characterized in the one optional route as subjecting the billet (1) towards upsetting and in next forging step forming the final basic structure of the Claw Pole component (3) with flash; and in the another optional route the billet is subjected to pre-forming the work-piece (6) in hot or warm condition and in next forging step forming the same final basic structure of the Claw Pole component (3) with flash, as that of first optional route.
4. Process for manufacturing Claw Pole involves continuous two-step forging operations, as claimed in claim 1, wherein said two-step forging is characterized in the final Claw Pole component (3) with flash, having same basic structural features, irrespective of substantially different intermediate embodiments formed during first step forging in said two optional routes.
5. Process for manufacturing Claw Pole involves continuous two-step forging operations, as claimed in claim 1, wherein basic Claw Pole component (3) with flash is subjected to trimming, preferably warm trimming just after the forging operation in continuation towards removal of the flash (5) from the body of the Claw Pole (4).
6. Process for manufacturing Claw Pole involves continuous two-step forging operations, as claimed in claim 1, wherein the trimmed body of the Claw Pole (4) is subjected to sizing, preferably in cold condition, and further to central hole drilling and further machining.
7. Process for manufacturing Claw Pole involves continuous two-step forging operations, as claimed in claim 1, wherein for performing said two-step forging the forging press with two optional press stations is chosen, wherein said optional two press stations are provisioned with open Punch and Die arrangements, optionally as (7) with (8) or (11) with (12) respectively, in vertical position.