Flow formed drum with a retention ring and a substantially burr free tooth profile
A flow formed part includes a first end, a second end, and a side wall extending therebetween. A reinforcing member is disposed around the second end. The side wall has a profile formed along an inner surface of the side wall. The profile is adapted to be substantially burr free after windows are formed in the sidewall. A method of making a flow formed part includes the steps of disposing a preform on a tailstock, providing a plurality of rollers adjacent the tailstock, providing a mandrel having an outer surface including a plurality of alternating channels and protuberances, and causing the rollers to press the preform against the outer surface of the mandrel.
1. A method for making a flow formed part comprising the steps of:
disposing a preform on a tailstock;
providing a plurality of rollers adjacent the tailstock;
providing a mandrel having a first end adapted to receive the preform, a second end disposed opposite the first end, and an outer surface including a plurality of alternating channels and protuberances extending therebetween;
causing the rollers to press the preform against the outer surface of the mandrel to form the flow formed part, wherein the flow formed part includes an inner surface with a profile formed thereon including a plurality of alternating channels and protuberances, wherein each of the protuberances formed on the inner surface of the flow formed part corresponds to one of the channels on the outer surface of the mandrel, and each of the channels formed on the inner surface of the flow formed part corresponds to one of the protuberances on the outer surface of the mandrel;
removing the flow formed part from the mandrel;
forming an integral reinforcing member on the flow formed part by one of a flow forming process and a secondary manufacturing process; and
forming a window in each of the channels of the flow formed part between adjacent ones of the protuberances of the flow formed part, wherein the window of each of the channels is entirely bounded by a portion of the flow formed part and the integral reinforcing member.
2. The method according to claim 1 , wherein the window in each of the channels is formed by one of a punching process and a machining process.
3. The method according to claim 2 , wherein the window in each of the channels is formed by the punching process.
4. The method according to claim 1 , wherein the second end of the mandrel includes a portion adapted to form the reinforcing member on the flow formed part when the preform is pressed against the mandrel.
5. The method according to claim 1 , wherein the reinforcing member has a diameter greater than a diameter of a side wall of the flow formed part.
6. The method according to claim 1 , wherein each of the protuberances on the outer surface of the mandrel includes a surface having a first portion extending outwardly from one adjacent channel, a second portion extending outwardly from another adjacent channel, and a third portion connecting the first portion and the second portion.
7. The method according to claim 6 , wherein the third portion of the surface of each of the protuberances of the outer surface of the mandrel is substantially planar.
8. The method according to claim 6 , wherein the third portion of the surface of each of the protuberances of the outer surface of the mandrel is non-planar.
9. The method according to claim 6 , wherein each of the channels of the outer surface of the mandrel includes a planar surface having a concave portion.
10. The method according to claim 6 , wherein the first portion of the surface of each of the protuberances of the outer surface of the mandrel is connected to a first adjacent channel of the outer surface of the mandrel by a first rounded interior corner and the second portion of the surface of each of the protuberances of the outer surface of the mandrel is connected to a second adjacent channel of the outer surface of the mandrel by a second rounded interior corner.
11. The method according to claim 1 , wherein the mandrel includes a rounded edge integrally connecting each of the channels on the outer surface of the mandrel with an adjacent protuberance on the outer surface of the mandrel.
12. A method for making a flow formed part comprising the steps of:
disposing a preform on a tailstock;
providing a plurality of rollers adjacent the tailstock;
providing a mandrel having a first end adapted to receive the preform, a second end disposed opposite the first end, and an outer surface including a plurality of alternating channels and protuberances extending therebetween;
causing the rollers to press the preform against the outer surface of the mandrel to form the flow formed part, wherein the flow formed part includes an inner surface with a profile formed thereon including a plurality of alternating channels and protuberances;
removing the flow formed part from the mandrel;
forming a plurality of windows in each of the channels of the flow formed part between adjacent ones of the protuberances of the flow formed part before forming; and
forming an integral reinforcing member on the flow formed part by one of a flow forming process and a secondary manufacturing process, wherein the integral reinforcing member is a retention ring and defines a portion of each of the plurality of windows.
13. The method according to claim 12 , wherein each of the protuberances formed on the inner surface of the flow formed part corresponds to one of the channels on the outer surface of the mandrel, and each of the channels formed on the inner surface of the preformed part corresponds to one of the protuberances on the outer surface of the mandrel.
14. The method according to claim 12 , wherein each of the protuberances on the outer surface of the mandrel includes a surface having a first portion extending outwardly from one adjacent channel, a second portion extending outwardly from another adjacent channel, and a third portion connecting the first portion and the second portion, the third portion substantially planar, and wherein each of the channels includes a planar surface having a concave portion.
15. The method according to claim 12 , wherein the second end of the mandrel includes a portion adapted to form the reinforcing member on the flow formed part when the preform is pressed against the mandrel.
16. A system for making a flow formed part comprising:
a tailstock configured to receive a preform;
a plurality of rollers adjacent the tailstock;
a mandrel having a first end adapted to receive the preform when the rollers press the preform against the mandrel, a second end disposed opposite the first end, and an outer surface including a plurality of alternating channels and protuberances extending between the first end of the mandrel and the second end of the mandrel, wherein the alternating channels and protuberances define a tooth profile of the flow formed part that permits the formation of substantially burr free windows and a retention member, wherein the second end of the mandrel includes a portion configured to form a reinforcing member around the preform when the preform is pressed against the mandrel, and wherein the reinforcing member is a ring and has a diameter greater than a diameter of a side wall of the preform.
17. The method according to claim 16 , wherein each of the protuberances includes a surface having a first portion extending outwardly from one adjacent channel, a second portion extending outwardly from another adjacent channel, and a third portion connecting the first portion and the second portion, the third portion substantially planar, and wherein each of the channels includes a planar surface having a concave portion.