Rolling tools for sheet thicknesses up to 6 mm – tolerances in the range of 0.15 mm
High-precision “thick sheet metal parts”
Transmission components and brake components are usually rotationally symmetrical and very precise. In order to transmit high forces or torques, many of the components must also have high rigidity or torsional stiffness. For a corresponding function (force transmission), this also means a corresponding component strength or thickness.
Various components in automatic, dual-clutch, and hybrid transmissions are therefore made from sheet metal with a thickness of 3 mm, 4 mm, or 5 mm. In exceptional cases, 6 mm or more is also used. In order to avoid imbalances or vibrations, the precision requirements are very high despite the component thickness.
These formed parts are manufactured using Precision Forming tools on progressive or transfer presses. Lamella carriers, clutches, converters, synchronizer rings, or carriers can therefore be produced very cost-effectively. Rolling tools are a special feature here. These special tools are used to manufacture the lamella carriers. Another application is the carriers for brake discs.
Rolling tools
The combination of thick sheet metal and high precision is the special expertise of Precision Forming. In order to achieve high precision, our rolling tools are used in conjunction with fine blanking technology. This minimizes tolerances.
Only a few toolmakers have mastered this technology. The most complex component had 24 steps (including four empty steps and feed) distributed across two tools with 14 and 10 steps. The lamella carrier was ultimately manufactured in 20 steps. The steps at a glance:
Tool 1:
- Cutting (level 1)
- Pulling, shaping, folding, perforating (levels 2 to 5)
- Rolling (levels 6, 8, and 10)
- Refolding (level 12)
- Trimming and punching (levels 13 and 14)
Tool 2:
- Punching (levels 2 and 3)
- Cutting (levels 4 and 6)
- Calibrating gear teeth (level 7)
- Punching (levels 8 to 11)
Do you have any questions about rolling tools or would you like to start working with us? Then don't hesitate to contact us—we are looking forward to hearing from you!
At Precision Forming, we have been working with rolling tools for a long time. Our persistence has resulted in many satisfied customers and our own patents in this field.
