Tooling and process control for splitting of disk blanks

Conventional splitting processes are today applied to manufacturing pulleys and flywheels from disk blanks. Usually, the splitting process is performed on a modified spinning lathe. However, the attainable radial splitting depths are limited and, to increase the formability of the machined part, new process concepts have to be developed. An innovative approach is the so-called flow-splitting process. In this case the tool configuration consists of three rolls, one splitting roll and two supporting rolls. While the splitting roll causes the workpiece material to flow into the two flange areas, the supporting rolls interact with the workpiece underneath the deformation zone. The distance between the splitting roll and each supporting roll can be adjusted to a specified value. Thus, the generated flange areas are given a predefined thickness. During the beginning of the forming process, the supporting rolls keep the workpiece from buckling. Once the edge of the blank has some deformation, the supporting rolls induce compressive stresses and thus increase the formability of the blank. In realizing the process concept, the described properties have to be transferred to a tooling system. Simultaneously, process control and measuring methods have to be developed.