Method for manufacturing poly-V pulleys

Claim 1

An improved method for manufacturing a poly-v pulley for use with a poly-V belt, from a cup-shaped blank having a substantially cylindrical flange wall, comprising the steps of: corrugating the flange wall to form a plurality of roughly dimensioned grooves, innermost edges of the grooves defining an inner surface of the flange wall; axially compressing the corrugated flange wall between a pair of press forms; and, pressing a rotatable finishing roller into each of the compressed grooves of the corrugated flange wall to form a plurality of poly-V grooves of predetermined shape; wherein the improvement comprises the steps of: supporting the flange wall from the inside, during the axial compression, by an inner form having an even outer surface which contacts the inner surface of the flange wall; supporting the flange wall from the outside during the axial compression by inserting an auxiliary roller into each of the grooves in the outer surface of the flange; and, allowing the auxiliary rollers to move axially so as to remain in engagement with the grooves as the flange wall is compressed.

Claim 3

A method for manufacturing a poly-V pulley for use with a poly-V belt, from a cup-shaped blank having a substantially cylindrical flange wall, comprising the steps of: corrugating the flange wall to form a plurality of roughly dimensioned grooves, innermost edges of the grooves defining an inner surface of the flange wall; axially compressing the corrugated flange wall between a pair of press forms, while simultaneously: supporting the flange wall from the inside by an inner form having an even outer surface which contacts the inner surface of the flange wall; supporting the flange wall from the outside by inserting an auxiliary roller into each of the grooves of the outer surface of the flange; and, allowing the auxiliary rollers to move axially so as to remain in engagement with the grooves as the flange wall is compressed; and, pressing a rotatable finishing roller into the compressed grooves of the flange wall to form a plurality of poly-V grooves of predetermined shape.

Claim 4

A method for manufacturing a poly-V pulley for use with a poly-V belt, from a cup-shaped blank having a substantially cylindrical flange wall, comprising the steps of: corrugating the flange wall to form a plurality of roughly dimensioned grooves, innermost edges of the grooves defining an inner surface of the flange wall; axially compressing the corrugated flange wall between a pair of press forms, while simultaneously: supporting the flange wall from the inside by an inner form having an even outer surface which contacts the inner surface of the flange wall; supporting the flange wall from the outside by inserting an auxiliary roller into each of the grooves of the outer surface of the flange; and, allowing the auxiliary rollers to move axially so as to remain in engagement with the grooves as the flange wall is compressed; and, pressing a rotatable finishing roller into the compressed grooves of the flange wall to form a plurality of poly-V grooves of predetermined shape.

Claim 6

A method according to claims 2 or 3, wherein the auxiliary rollers are formed from a single roller having a plurality of roller ribs projecting outwardly therefrom.

Claim 7

A method according to claims 2 or 3, wherein the auxiliary rollers are individual members mounted on a common shaft.

Claim 8

A method according to claims 2 or 3, further comprising the step of rotating the press forms during the axial compression.

Claim 9

A method according to claims 4 or 5, wherein the auxiliary forming rollers are freely slidably attached to shafts disposed parallel to the central axis of the blank.

Claim 10

A method according to claims 4 or 5, further comprising the steps of: dividing the grooves, as determined from the outer surface of the flange wall, into two sets of alternating valleys; positioning two shafts parallel to the central axis of the blank so as not to interfere with each other; attaching a plurality of auxiliary forming rollers on one of the shafts, each of the rollers being mounted so as to be inserted into one of the valleys of one of the alternating sets; and, attaching a further plurality of auxiliary forming rollers on the other of the shafts, each of the rollers being mounted so as to be inserted into the valleys of the other of the alternating sets.