(19) TZZ¥ _Z T

(11) EP 3 246 106 A2

(12) EUROPEAN PATENT APPLICATION

(43) Date of publication: (51) Int Cl.: 22.11.2017 Bulletin 2017/47 B21H 5/02 (2006.01) B21H 3/06 (2006.01)

(21) Application number: 17155302.7

(22) Date of filing: 21.05.2013

(84) Designated Contracting States: (72) Inventor: CALLESEN, Michael David AL AT BE BG CH CY CZ DE DK EE ES FI FR GB Columbia Station, Ohio 44028 (US) GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR (74) Representative: Hirsch & Associés 137, rue de l’Université (30) Priority: 23.05.2012 US 201213478663 75007 Paris (FR)

(62) Document number(s) of the earlier application(s) in Remarks: accordance with Art. 76 EPC: This application was filed on 08-02-2017 as a 13793260.4 / 2 855 044 divisional application to the application mentioned under INID code 62. (71) Applicant: U.S. Gear Tools, Inc. Detroit, Michigan 48205 (US)

(54) SPLINE ROLLING RACK AND METHOD FOR PREPARING A SPINE ROLLING RACK

(57) A spline rolling rack assembly for cold-forming load and work positions, and multiple clamping assem- external surface configurations upon a metal workpiece blies disposed within said carriage for releasably secur- is provided, having a durable carriage of the type secured ing the rack insert upon the carriage. The perishable rack upon a reciprocating slide assembly, a perishable rack insert is designed for quick and convenient replacement, insert that is removably secured upon the carriage, a lo- reducing maintenance cost and idle time for these devic- cating key disposed between the rack insert and the car- es. The single-use nature of the insert relieves the user riage for properly aligning the rack insert upon the car- from the burden of managing an inventory of like tools, riage, a locating assembly disposed upon the carriage in various states of use, in order to ensure that new tools and engageable with the rack insert for assisting in prop- are ordered in a timely manner for replacing tools that erly aligning the rack insert and the carriage between have exhausted their useful life. EP 3 246 106 A2

Printed by Jouve, 75001 PARIS (FR) 1 EP 3 246 106 A2 2

Description [0005] The nature of forming the desired power/torque transmission features, such as splines, requires critical [0001] This application is a divisional application of Eu- tolerances in the size and configuration of the feature- ropean patent application No. 13793260.4 filed on May forming surfaces, and well as in the spacing, configura- 21, 2013. 5 tion and movement of the racks so that the desired sur- face features are accurately formed in the workpiece. FIELD Thus, these tooling components require precision-craft- ed feature-forming surfaces and precision mounting ap- [0002] The present disclosure relates generally to ma- paratus, supports and fasteners within the larger ma- chines for forming external surface configurations upon 10 chines in which they are typically contained. However, metal workpieces by pressure-applied material displace- these tooling components have a limited lifespan, with ment, and is more specifically directed to spline rolling their feature-forming surfaces typically becoming worn rack assemblies, components, tooling and devices for or no longer within required tolerances after some period securing and manipulating such tooling. The present dis- of their use. closure also relates to methods for roll-forming splines 15 [0006] Accordingly, at periodic intervals it is typically on the external surfaces of axle, shaft and other pow- necessary to remove the surface-forming tooling com- er/torque transmission components of the type used in ponents for replacement or resurfacing. Such compo- vehicles, machines, commercial and industrial equip- nents can typically be resurfaced a number of times be- ment and other devices. fore they can no longer be resurfaced, and as such, must 20 then be replaced. Oftentimes, the manufacture and re- BACKGROUND surfacing of such tooling components is inefficient due to the time required to ship the components back to the [0003] This section provides background information manufacturer for resurfacing and back again to the user. related to the present disclosure which is not necessarily Also, oftentimes, removal and replacement of such tool- prior art. 25 ing components is time-consuming, burdensome and [0004] The manufacture of axle, shaft and other pow- otherwise inefficient, due to the configuration and large er/torque transmission components of the type used in size of the components, the current way in which the vehicles, machines, commercial and industrial equip- tooling components are secured in a work position, and ment and other devices often requires the formation of the positioning and aligning activities that must typically power/torque transmission features upon the external 30 take place for securing the components in a work posi- surfaces of round metal workpieces, in the form of rods, tion. Having such a machine in an idle state during re- tubes, cylinders and other shapes. One exemplary man- quiredmaintenance activities slows down overall produc- ufacturing method involves spline rolling, which typically tion rates for any such affected facility, so it is advanta- utilizes a pair of opposed, elongated, substantially par- geous for such maintenance to be made convenient, ef- allel, reciprocating dies, tools or tool members (called 35 ficient and quick. "racks")having a seriesof feature-forming surfaces,such [0007] As examples, the tooling components requiring as teeth, disposed in precision arrangements on facing repair or replacement may be secured within the interior surfaces thereof corresponding to, but not necessarily of a larger machine in a way that is inconvenient to man- matching, the desired final surface features of the work- age, such as being secured with fasteners, such as bolts piece to be prepared. Accordingly, spline rolling typically 40 and set screws, that are difficult to reach and manipulate. involves reciprocating movement of the opposed dies, In addition, the end of a spline rolling rack is typically the tools or tool members (called "racks") over the length of primary locating surface for gauging the proper mounting a rotating workpiece, in opposite directions and in over- location of the rack within the machine, which can be lapping relationship, causing the feature-forming surfac- inconvenient to measure or check for proper alignment. es to displace material upon the surface of the rotating 45 Also, the tooling components may not themselves be workpiece by applied pressure, in a cold-forming tech- manufactured in sufficient tolerances for precision work, nique. The spline rolling operation thus forms the desired or the devices or features provided for facilitating proper finished external surface features in the workpiece, typ- positioningmay not be sufficient or efficientto use. Proper ically helical or spur ridges, teeth or grooves (oralignment of the tooling components relative to each oth- "splines"), through the combination of the rotation of the 50 er must typically be ensured, which may only be provided workpiece with the linear reciprocating movement of the in limited scope by relative adjustment of certain surfaces racks. Spline rolling racks are typically constructed in sin- on the machine components when located within the ma- gle or double-piece form, with either the single piece or chine that can be difficult to reach and/or examine. The both pieces of a double-piece rack being perishable. final tolerances required in the feature-forming surfaces They are typically fastened upon suitable opposed, elon- 55 may also not be sufficient, or may be manufactured in- gated, substantially parallel, reciprocating slide assem- efficiently, such as by preparing the feature-forming sur- blies located within dedicated spline rolling machines of faces to required precision tolerances as the final step industrial grade. of the manufacturing process.

2 3 EP 3 246 106 A2 4

[0008] In addition, there is typically a substantial cost Also, the locating key may preferably be secured to said associated with the replacement or repair of the tooling carriage by a locating bolt. components involved in such surface forming operations. [0013] The spline rolling rack assembly further com- The sizes of the components can be substantial, depend- prises a locating assembly operable for being disposed ing upon the sizes of the power/torque transmission com- 5 upon the carriage in movable relation between a first po- ponents being manufactured, perhaps requiring substan- sition corresponding to a loading position of the rack in- tial powered lifting equipment for assisting in this activity. sert upon the carriage and a second position correspond- The repair or replacement of the tooling components may ing to a work position of the rack insert upon said carriage. require shipment and/or courier delivery of substantially- The locating assembly is also operable for engaging a sized and weighted components, at considerable ex-10 recess within the rack insert, wherein movement of the pense. Users of such tooling components must also man- locating assembly from the first position to the second age a float of such tools at various levels of life and, due position engages the locating assembly with the recess to the lead time required to manufacture new racks, must within the rack insert to assist in properly aligning the anticipate tools ending their life span and order new tools rack insert upon the carriage in at least one of a load to arrive in conjunction with the retirement of existing15 position and a work position. tools. [0014] The spline rolling rack assembly further com- [0009] In consideration of the above, the adoption of prises a plurality of clamping assemblies disposed at an improved configuration of such surface-forming tool- spaced apart locations longitudinally within the carriage, ing components along with an improved configuration of eachclamping assemblyoperable for releasably contact- the associated devices used for retaining such compo- 20 ing the rack insert in a pressurized manner for securing nents in required locations while maintaining the required the rack insert in a fixed work position upon the carriage, tolerances for same, would provide significant mainte- wherein each clamping assembly is operable for being nance efficiencies and cost benefits. adjusted between a released unclamped condition and an engaged clamped condition. SUMMARY 25 [0015] Further areas of applicability will become ap- parent from the description provided herein. The descrip- [0010] This section provides a general summary of the tion and specific examples in this summary are intended disclosure, and is not a comprehensive disclosure of its for purposes of illustration only and are not intended to full scope or all of its features. limit the scope of the present disclosure. It will be appre- [0011] The present disclosure provides a spline rolling 30 ciated that the above principles may be applied to devices rack assembly for cold-forming external surface config- for forming other types of external surface configurations urations upon a metal workpiece, comprising a durable upon other workpieces as well. carriage operable for being fixedly secured upon a recip- rocating slide assembly within a machine for forming ex- DRAWINGS ternal surface configurations upon said metal workpiece. 35 The carriage includes a mounting surface and is operable [0016] The drawings described herein are for illustra- for sliding in reciprocating relation together with rotation tive purposes only of selected embodiments and not all of the workpiece. The spline rolling rack assembly further possible implementations, and are not intended to limit comprises a perishable rack insert that is operable for the scope of the present disclosure. being removably secured upon said mounting surface of 40 said carriage, the rack insert having a working surface FIG. 1 is a front cross-sectional view of the spline with a series of feature-forming surfaces formed there- rolling carriage and rack insert in an unsecured load- upon for cold-forming external surface configurations up- ing position, according to the present disclosure. on a metal workpiece. The rack insert is operable for FIG. 2 is a front cross-sectional view of the spline being removed from, and secured upon, the carriage 45 rolling carriage and rack insert in a secured working within the machine without removing the carriage from position, according to the present disclosure. within the machine. FIG. 3 is a cross-sectional plan view of the spline [0012] The spline rolling rack assembly further com- rolling carriage and rack insert in a secured working prises a locating key operable for being disposed be- position, according to the present disclosure. tween a first locating key recess formed within the rack 50 FIG. 4 is a front cross-sectional view of the spline insert and a second locating key recess formed within rolling carriage and rack insert in a secured working the carriage for properly aligning the rack insert upon the position, also showing the clamp pins in the secured carriage in at least one of a load position and a work working position as well as the actuator used to ma- position. Manufactured configurations of the locating key nipulate the insert between the unsecured loading and the first and second locating key recesses together 55 position and secured working position of the associ- comprise the primary engaging components and surfac- ated locating assembly, according to the present dis- esfor properly aligning said rackinsert upon saidcarriage closure. in at least one of a load position and a work position. FIG. 5 is an end cross-sectional view of the associ-

3 5 EP 3 246 106 A2 6

ated clamping assembly for the spline rolling car- DETAILED DESCRIPTION riage and rack insert in a secured working position, according to the present disclosure. [0018] Example embodiments will now be described FIG. 6 is an end cross-sectional view of the associ- more fully with reference to the accompanying drawings. ated clamping assembly for the spline rolling car- 5 [0019] FIG. 1 illustrates a spline rolling rack assembly, riage and rack insert in an unsecured loading or generally at 10, in a loading position, prior to being shifted working position, according to the present disclo- to the working position illustrated in FIG. 2. The spline sure. rolling rack assembly 10 is a component of a larger, ded- FIG. 7 is an end cross-sectional view showing the icated, machine of industrial grade (not shown) for form- associated locating assembly for the spline rolling 10 ing external surface configurations, such as helical or carriage and rack insert, according to the present spur ridges, teeth or grooves (or "splines") upon round disclosure. metal workpieces in the form of rods, tubes, cylinders FIG. 8 is an end cross-sectional view showing a car- and other shapes. The spline rolling rack assembly 10 riage retention bolt and inner and outer datum rail includes a carriage 12 of the type capable of being fixedly fasteners for the spline rolling carriage and rack in- 15 secured upon a reciprocating slide assembly (also not sert, according to the present disclosure. shown) within the machine, for sliding in reciprocating FIG. 9A is an enlarged composite view of the asso- relation together with rotation of a workpiece. The car- ciated locating assembly for the spline rolling car- riage 12 is shown to include a carriage mounting surface riage and rack insert illustrating its function among 14, as well as a plurality of carriage retention apertures multiple positions, according to the present disclo- 20 13, through which the carriage 12 is secured to the re- sure. ciprocating slide assembly by a plurality of carriage re- FIG. 9B is an enlarged view of the associated locat- tention bolts 15. ing assembly for the spline rolling carriage and rack [0020] The spline rolling rack assembly 10 also in- insert in a clamped working position, according to cludes a rack insert 16 having a working surface 18 that the present disclosure. 25 includes a plurality of feature-forming surfaces, shown in FIG. 9C is an enlarged view of the associated locat- the form of teeth 20, formed upon the working surface ing assembly for the spline rolling carriage and rack 18. It will be appreciated that any other suitable feature- insert in a loading position, according to the present forming surfaces may also be formed upon the working disclosure. surface 18, depending on the surface configurations de- FIG. 9D is an enlarged view of the associated locat- 30 sired upon the workpiece. The rack insert 16 is designed ing assembly for the spline rolling carriage and rack to be removably secured upon the carriage mounting sur- insert in an unclamped working position, according face 14 in a quick and convenient way, without requiring to the present disclosure. the use of extensive bolts or other individual fasteners. FIG. 10 is an end cross-sectional view of an alternate Accordingly, the rack insert 16 is intended to be quickly associated clamping assembly for the spline rolling 35 and conveniently removed from its position upon the car- carriage and rack insert in a secured working posi- riage 12, and replaced into its position and secured upon tion, according to the present disclosure. the carriage 12, whenever repair or replacement of the FIG. 11 is an enlarged front cross-sectional view of rack insert 16 is required. The present invention thus pro- an alternate associated clamping assembly for the vides a dual-component assembly wherein the carriage spline rolling carriage and rack insert in a secured 40 12 remains within the larger machine, while only the rack working position, according to the present disclo- insert 16 is removed and replaced. The configurations sure. and dimensions of the feature-forming surfaces, the car- FIG. 12 is an enlarged view of an alternate associ- riage 12 and the remainder of the rack insert 16 are man- ated clamping assembly recess machined directly ufactured to precision tolerances in configurations and into the rack insert, according to the present disclo- 45 dimensions as may be necessary for creating the re- sure. quired tolerances of configurations and dimensions in FIG. 13 is an enlarged view of a locating key for the the surface configurations being formed upon the work- spline rolling carriage and rack insert in a loading piece. position, as shown in FIG. 1, according to the present [0021] The present arrangement therefore contem- disclosure. 50 plates eliminating use of prior perishable single-piece FIG. 14 is an enlarged view of a locating key for the racks or a double-piece racks wherein both pieces are spline rolling carriage and rack insert in a secured perishable in favor of a two-piece tooling assembly hav- working position, as shown in FIG. 2, according to ing adurable carriage supporting a perishable rackinsert. the present disclosure. Such an arrangement is believed to greatly enhance the 55 convenience and speed for removing and replacing the [0017] Corresponding reference numerals indicate rack inserts 16, which in turn will reduce the time that the corresponding parts throughout the several views of the spline rolling machine is idle for maintenance. In addition, drawings. the rack inserts 16 are preferably designed for a single

4 7 EP 3 246 106 A2 8 use, although they may also be refinished and reused as 16 upon the carriage 12 (represented by the position of many times as permitted by the required specifications the lock pin 32 in FIG. 1) and a second position corre- and tolerances of the tooling equipment being used and sponding to a work position of the rack insert 16 upon the workpieces being treated. Because the rack inserts the carriage (represented by the position of the lock pin 16 can be of significantly smaller dimensions than a sin- 5 32’ in FIG. 2). The counter-clockwise rotation of the lock gle-piece rack of the type common in previous devices, pin 32 and lock shaft 34 together is accompanied by a the new rack inserts 16 of the present invention can be longitudinal sliding movement of the rack insert 16 upon handled and shipped much more quickly, more conven- the mounting surface 14 of the carriage 12 between a iently and at lower cost. load position for the assembly (represented by the des- [0022] As shown in FIGS. 1, 2, 13 and 14, the spline 10 ignation 10 in FIG. 1) to a work position for the assembly rolling rack assembly 10 further includes a locating key (represented by the designation 10’ in FIG. 2). In similar 22 that is disposed between a first locating key recess fashion, the load position and work position for the rack 24 formed within the rack insert 16 and a second locating insertare designatedas 16 and 16’,respectively, inFIGS. key recess 26 formed within the carriage 12. The locating 1 and 2. Rotation of the lock pin 32 and lock shaft 34 in key 22 is secured to the carriage 12 by a locating bolt 15 a clockwise direction (from 32’ in FIG 2 to 32 in FIG. 1) 28. The locating key recess 24 also includes a primary returns the assembly from a work position (10’ in FIG. 2) stop surface 33, which represents the primary location to a load position (10 in FIG. 1) for removal and replace- on the rack insert 16 that bears against the locating key ment of the rack insert 16. Accordingly, the movement 22. In the manufacture of a cooperating pair of rack in- of the locating assembly 30 in this manner assists in prop- serts 16, the working surface 18 of each rack insert 16 20 erly aligning the rack insert 16 upon the carriage 12 be- is ground to specified tolerances while utilizing each pri- tween a load position and a work position. Load arrows mary stop surface 33 as the primary locating datum for 35 and 37 are provided in the form of indicia disposed each rack insert 16, thus ensuring that the rack inserts upon, or alternately imprinted into, the external side sur- 16 are synchronized. The locating key 22, in connection faces of the rack insert 16 and carriage 12, respectively, with the first locating key recess 24 and the second lo- 25 for assisting in the alignment of the rack insert 16 upon cating key recess 26, together comprise the primary en- the carriage 12 in a load position. As shown in FIG. 2, gaging components and surfaces for properly aligning movement of the rack insert 16 longitudinally upon the the rack insert 16 upon the carriage mounting surface 14 carriage 12 from a load position to a work position dis- of the carriage 12 in a load position, as illustrated in FIGS. places the load arrow 35 to the location referenced at 1 and 13, as well as in a work position, as set forth below 30 35’. Movement of the rack insert 16 from the work position in connection with FIGS. 2 and 14 (wherein the spline back to the load position realigns the load arrows to en- rolling rack assembly is referenced at 10 and the rack sure that the rack insert 16 is in the proper position for insert is designated at 16’). Accordingly, the manufac- removal from upon the carriage 12. tured configurations and dimensions of the locating key [0024] FIGS. 3 and 4 show a cross-sectional plan view 22, the first locating key recess 24 and the second locat- 35 and a front cross-sectional view, respectively, of the ing key recess 26 are prepared to sufficiently precise spline rolling carriage and rack insert of the spline rolling tolerances for providing sufficiently precise tolerances in carriage and rack insert in a secured working position. the positionof thefeature-forming surfaces of the working From this view, the carriage retention bolts 15 are shown surface 18 of the rack insert 16. Use of the locating key as being disposed within carriage retention apertures 13. 22 is believed to provide a quicker and more easily ac- 40 The carriage retention bolts 15 are operable for securing cessed method for aligning the rack insert 16 upon the the carriage 12 to the reciprocating slide assembly (not carriage 12 than would be possible through other, man- shown). In addition, there are shown a plurality of inner ual, alignment methods that might rely on visual or tactile and outer datum rail fasteners 17 and 19, which secure inspection of the various component surfaces. the inner and outer datum rails 40 and 42, respectively, [0023] The spline rolling rack assembly 10 further in- 45 to the carriage 12. cludes a locating assembly, generally at 30. The locating [0025] FIG. 8 shows in greater detail an end cross- assembly 30 includes a lock pin 32 attached to a lock sectional view of a carriage retention bolt 15 disposed shaft 34 that is rotatably disposed within a first locating through a carriage retention aperture 13 for securing the assembly recess 36 of the carriage 12. It will be appre- carriage 12 to a reciprocating slide assembly. Inner and ciated that multiple lock pins 32 may be employed, de- 50 outer datum rail fasteners 17 and 19 (also shown in FIG. pending on the application. The lock pin 32 extends from 3) are shown to secure the inner datum rail 40 and the the lock shaft 34 outwardly from within the first locating outer datum rail 42, respectively, in place upon the car- assembly recess 36 of the carriage 12 to within a second riage 12. locating assembly recess 38 of the rack insert 16, which [0026] The components of the locating assembly 30 forms a stop for movement of the rack insert 16 once it 55 are shown in greater detail with reference to FIG. 7, reaches a work position. The lock pin 32 and lock shaft viewed in a longitudinal direction. FIG. 7 shows the rack 34 are together capable of being rotated between a first insert 16 disposed upon the carriage 12. However, in this position corresponding to a load position of the rack insert view, it can be seen that the carriage 12 includes inner

5 9 EP 3 246 106 A2 10 datum rail 40 and outer datum rail 42 upon which the rack fixed work position upon the carriage 12, once the rack insert 16 is positioned, which serve as locating and/or insert 16 has been moved from the load position to the alignment rails in both load and work positions of the work position. Each clamping assembly is operable for assembly 10. The rack insert 16 includes a male rack being adjusted between a released unclamped condition alignment protrusion 44 that fits between the inner and 5 and an engaged clamped condition. The clamping as- outer datum rails 40 and 42, such that the longitudinal semblies operate by cam mechanisms which secure the orientation of the rack insert 16 is determined by a close rack insert 16 relative to the carriage 12 by a pressure fit between the rack alignment protrusion 44 and the in- action, which is believed to be more quickly and conven- terior surfaces of the inner and outer datum rails 40 and iently operated than the use of numerous individual bolts 42. The lock pin 32 and lock shaft 34 are shown to engage 10 for securing these components together. a compression spring 46 which forces the lock pin 32 and [0029] The components and functions of the clamping lock shaft 34 among two counter-clockwise positions be- assemblies will be discussed in greater detail with refer- tween an unclamped, but compressed, condition, and a ence to FIGS. 5, 6 and 10, which show alternate embod- clamped, partially-relaxed but engaged condition, which iments of clamping assembly configurations, generally in turn correspond to the load position, work position (un- 15 referenced with the numerals 48 and 48’. As with the clamped) and work position (clamped) of the assembly locating assembly 30, the clamping assemblies 48 and 10 respectively, as previously described. 48’ are each constructed as part of the carriage 12, but [0027] The various operating positions of the locating also each engage a clamping assembly recess 56 within assembly 30 are shown in greater detail with reference the rack insert 16. As shown in FIG. 5, the clamping as- to FIGS. 9A-9D, viewed in an enlarged upper cross-sec- 20 sembly 48 includes a cam 58 disposed within the carriage tional view. FIG. 9A is a composite view of the locating 12 that is accessible from the exterior of the carriage 12 assembly illustrating its function among the multiple po- through Allen wrench recess 63, and engages a clamp sitions of the lock pin 32 during operation of this assem- pin 60. The clamping assembly 48 also includes a key- bly. Operation of the locating assembly 30 is accom- hole insert 62 disposed against the rack insert 16 defining plished through the insertion of an Allen wrench (not25 a passage for the clamp pin 60 to travel through for en- shown) into the Allen wrench recess 31 of the lock shaft gaging the clamping assembly recess 56, as well as a 34, and subsequent rotation of the lock shaft 34. FIG. 9C stop for release of the clamp pin 60. Accordingly, the lock shows the locating assembly 30 in a loading position, pin 60 is held in the assembly by virtue of its interface with the lock pin 32 in a first position corresponding to with the cam 58. The clamping assembly recess 56 also that condition. FIG 9D shows the locating assembly in 30 includes a snap ring 64 for retaining the keyhole insert an unclamped working position, resulting from rotation 62 in place and an anti-rotation pin 65 for providing proper of the lock shaft 34 in a counter-clockwise manner, which orientation for the keyhole insert 62. Disc springs 66 are moves the lock pin to the position designated as 32". also provided at an end portion of the clamp pin 60 for Release of the lock shaft 34 from the position shown in providing a suitable clamping force when the cam 58 is FIG. 9D then allows the lock pin to move to the position 35 released, which are retained upon the clamp pin 60 by a designated at 32’ in FIG. 9B, which shows the locating snap ring 67. assembly 30 in a clamped working position. The locating [0030] The cam 58 and clamp pin 60 are shown in a assembly 30 is also shown to have a taper of five degrees clamped work condition in FIG. 5, and in an unclamped formed as a tapered recess side 39 of the second locating condition in FIG. 6. In the operation of this portion of the assembly recess 38 in the rack insert 16 through which 40 assembly, rotation of the cam from the configuration 58’ the lock pin 32 is disposed. In the operation of the locating shown in FIG. 6 into the configuration 58 shown in FIG. assembly 30, the lock pin 32 is forced against this taper 5 forces the clamp pin 60 downwardly toward the clamp- in the clamped working position and maintains bearing ing assembly recess 56 of the rack insert 16, thus placing of the locating key 22 against the primary stop surface the rack insert 16 and the carriage 12 in an engaged 33, which helps to retain the lock pin 32 in the desired 45 clamped condition. Similarly, rotation of the cam from the positions. Alternatively, it will be appreciated that other configuration 58 shown in FIG. 5 into the configuration suitable tapers besides five degrees could also be used. 58’ shown in FIG. 6 forces the clamp pin 60 upwardly [0028] Referring again to FIGS. 1-4, the spline rolling away from the clamping assembly recess 56 of the rack rack assembly 10 further includes a plurality of clamping insert 16, thus placing the rack insert 16 and the carriage assemblies, generally shown at 48, 50, 52 and 54. Four 50 12 in a released unclamped condition. When this activity clamping assemblies are shown in this example, al- is performed for multiple clamping assemblies disposed though it will be appreciated that any suitable number of longitudinally along the assembly 10, the rack insert 16 such clamping assemblies may be used depending on and the carriage 12 can be clamped in the work position the configuration, dimensions and load requirements of and unclamped, as desired. In each case, the clamping the assembly 10. The clamping assemblies 48, 50, 52 55 force on the rack insert 16 is spring pressure, as actuating and 54 are disposed at spaced apart locations longitudi- the clamp pin 60 as described above compresses and nally within the carriage 12, and operate to releasably decompresses the springs in order to unclamp and clamp secure the rack insert 16 in a pressurized manner in a the rack insert 16, respectively.

6 11 EP 3 246 106 A2 12

[0031] FIG. 10 shows an alternate construction for the insert 16 is positioned upon the mounting surface 14 of clamping assembly, generally referred to at 48’. Unlike the carriage 12 in such a manner that the load arrows 35 the embodiment shown in FIGS. 5 and 6, this embodi- and 37 are aligned, as shown in FIG. 1. In this condition, ment does not use a keyhole insert 62 or snap ring 64. the locating key 22 (which is secured upon the carriage Instead, in this embodiment, the clamping assembly re- 5 12 by the locating bolt 28) engages the first locating key cess 56 is machined directly into the rack insert 16. In recess 24 disposed within the rack insert 16. At the same similar manner as for the previous embodiment shown time, the clamp pin 60 engages the large radius recess in FIGS. 5 and 6, the clamping assembly 48’ also includes 59 of the clamping assembly recess 56 in the rack insert a cam 58 disposed within the carriage 12 that is acces- 16, as shown in FIG. 12. The locating assembly 30 is sible from the exterior of the carriage 12 through Allen 10 then actuated by the engagement of Allen wrench recess wrench recess 63, for engaging a clamp pin 60. In this 31 with a suitable Allen wrench, so that the lock shaft 34 embodiment, the clamping assembly recess 56 itself de- is rotated counter-clockwise, moving the rack insert 16 fines a passage for the clamp pin 60 to travel, as well as longitudinally relative to the carriage 12 into the working a stop for release of the clamp pin 60. Again, rotation of position (but unclamped) shown in FIG. 2. In this activity, the cam 58 forces the clamp pin 60 downwardly toward 15 the load arrows become displaced relative to each other, the clamping assembly recess 56 of the rack insert 16, as shown at reference numerals 35’ and 37’ in FIG. 2, thus placing the rack insert 16 and the carriage 12 in an and the lock pin moves from the loading position shown engagedclamped condition. Similarly, rotationof the cam at numeral 32 in FIG. 9C to the position shown at numeral 58 back to its previous position forces the clamp pin 60 32" in FIG. 9D, which represents the unclamped working upwardly away from the clamping assembly recess 56 20 position of the assembly. Release of the lock shaft 34 of the rack insert 16, releasing the clamp pin 60 from its then allows it to travel toward the front of the assembly pressurized contact with the recess 56 of the rack insert under spring pressure exerted by spring 46, shown in 16 and placing the rack insert 16 and the carriage 12 in FIGS. 3 and 7, which permits the lock pin to bear against a released unclamped condition. the tapered recess side 39 in the rack insert 16 in the [0032] FIG.11 shows anenlarged front cross-sectional 25 positiondesignated with thenumeral 32’ inFIG. 9b,which view of the alternate associated clamping assembly in a represents the clamped working position of the assem- secured working position. From this view, and in combi- bly. At the same time, this activity forces the locating key nation with FIG. 12, it can be seen that the clamping 22 to bear upon the primary stop surface 33, as shown assembly recess 56 has a small radius recess 57 and a in FIGS. 1, 2, 13 and 14. large radius recess 59, each formed as part of the clamp- 30 [0035] Securing the assembly in the clamped working ing assembly recess 56. The large radius recess 59 al- position also requires the release of cam 58 in each lows the clamp pin 60 to enter the clamping assembly clamping assembly 48, 50, 52 and 54 by engaging the recess 56 and corresponds to the load position. When Allen wrench recess 63 with a suitable Allen wrench and the rack insert 16 is moved to the work position, the un- rotating the cam 58 in either a clockwise or counter-clock- derside of the clamp pin 60 engages the small radius35 wise direction within the lock pin recess 61 such as to recess 57 by virtue of the applied pressure from disc the position marked as 58 in the embodiment shown in springs 66 once the cam 58 is released. FIG. 5 (and performed similarly in the embodiment illus- [0033] As shown in the longitudinal views of FIGS. 5, trated in FIG. 10). This in turn causes the clamp pin 60 6, 7 and 10, the primary contacting surfaces of the rack to travel in a manner away from the rack insert 16, which insert 16 against the inner and outer datum rails 40 and 40 partially relaxes the disc springs 66 and allows the clamp 42 of the carriage 12 are designated as the inner height pin 60 to bear on the clamping assembly recess 56. location datum 68 and outer height location datum 70. [0036] Removal of the rack insert 16 from upon the The inner height location datum 68 and outer height lo- carriage 12 involves releasing each clamping assembly cation datum 70 serve the function of being the surfaces 48, 50, 52 and 54 from the clamped to the unclamped that are manufactured to the closest tolerances (and typ- 45 condition while the overall assembly is in the working ically formed last in the manufacturing process of the rack position. To accomplish this (for each clamping assem- insert 16) so that the feature-forming surfaces (such as bly), the Allen wrench recess 63 is engaged with a suit- teeth 20) of the rack insert 16 can in turn be brought to able Allen wrench and rotated clockwise or counter- the closest configuration and dimension tolerances. It is clockwise within the lock pin recess 61, which causes believed that using the inner height location datum 68 50 the clamp pin 60 to travel toward the rack insert 16, re- and outer height location datum 70 in this way provides leasing the clamp pin 60 from bearing upon the clamping improved tolerances in a more efficient manner of man- assembly recess 56 and unclamping the assembly. The ufacturing the rack insert 16, as opposed to the previous assembly is then moved from the working position to the method of manufacturing the required tolerances (such loading position by actuating the locating assembly 30 as by grinding) into the feature-forming surfaces (such 55 by the engagement of Allen wrench recess 31 with a suit- as teeth 20) as the final manufacturing step of the rack able Allen wrench, so that the lock shaft 34 may be de- insert 16. pressed and then rotated clockwise, moving the rack in- [0034] In the method of the present disclosure, the rack sert 16 longitudinally relative to the carriage 12 into the

7 13 EP 3 246 106 A2 14 loading position shown in FIG. 1, with the load arrows ing said rack insert upon said carriage in at least moving from the unaligned positions shown at 35’ and one of a load position and a work position, and 37’ in FIG. 2 to the aligned positions shown at 35 and 37 wherein said locating key is secured to said car- in FIG. 1. Once in the loading position, the rack insert 16 riage; may be removed from upon the mounting surface 14 of 5 a locating assembly operable for being disposed the carriage 12. upon said carriage in movable relation between [0037] Since typical spline rolling racks include upper a first position corresponding to a loading posi- and lower spline rolling rack assemblies such as the as- tion of said rack insert upon said carriage and a sembly described herein, it will be appreciated that the second position corresponding to a work posi- above description of both apparatus and method typically 10 tion of said rack insert upon said carriage, said apply to both an upper and lower assembly, which must locating assembly also operable for engaging a both be installed and secured before operation of the recess within said rack insert, wherein move- overall spline rolling rack machine can begin. ment of said locating assembly from said first [0038] The foregoing description of the embodiments position to said second position engages said has been provided for purposes of illustration and de- 15 locating assembly with said recess within said scription. It is not intended to be exhaustive or to limit the rack insert to assist in properly aligning said rack disclosure. Individual elements or features of a particular insert upon said carriage in at least one of a load embodiment are generally not limited to that particular position and a work position; and embodiment, but, where applicable, are interchangeable a plurality of clamping assemblies disposed at and can be used in a selected embodiment, even if not 20 spaced apart locations longitudinally within said specifically shown or described. The same may also be carriage, each clamping assembly operable for varied in many ways. Such variations are not to be re- releasably contacting said rack insert in a pres- garded as a departure from the disclosure, and all such surized manner for securing said rack insert in modifications are intended to be included within the a clamped work position upon said carriage, scope of the disclosure. 25 wherein each clamping assembly is operable for [0039] The invention relates also to items below: being adjusted between a released unclamped condition and an engaged clamped condition. Item 1. A spline rolling rack assembly for cold-form- ing external surface configurations upon a metal Item 2. A spline rolling rack assembly according to workpiece, comprising: 30 item 1, wherein said locating assembly comprises a lock pin attached to a lock shaft rotatably disposed a durable carriage operable for being fixedly se- within said carriage and capable of being rotated be- cured upon a reciprocating slide assembly with- tween a first position corresponding to a load position in a machine for forming external surface con- of said rack insert upon said carriage and a second figurations upon said metal workpiece, said car- 35 position corresponding to a work position of said rack riage having a mounting surface, said carriage insert upon said carriage. operable for sliding in reciprocating relation to- Item 3. A spline rolling rack assembly according to gether with rotation of the workpiece; item 1, wherein each clamping assembly comprises a perishable rack insert operable for being re- a cam disposed within said carriage and operable movably secured upon said mounting surface 40 for engaging a clamp pin forming part of the clamping of said carriage, said rack insert having a work- assembly into an engaged clamped condition ing surface with a series of feature-forming sur- against said rack insert. faces formed thereupon for cold-forming exter- Item 4. A spline rolling rack assembly according to nal surface configurations upon a metal work- item 1, wherein each clamping assembly is operable piece, said rack insert operable for being re-45 for engaging a recess within said rack insert, and moved from, and secured upon, said carriage wherein adjustment of said clamping assembly from within said machine without removing said car- a released unclamped condition to an engaged riage from within said machine; clamped condition operates to engage a clamp pin a locating key operable for being disposed be- forming part of the clamping assembly against said tween a first locating key recess formed within 50 recess within said rack insert. said rack insert and a second locating key re- Item 5. A spline rolling rack assembly according to cess formed within said carriage for properly item 1, wherein said carriage includes longitudinally aligning said rack insert upon said carriage in at disposed inner and outer datum rails for engaging a least one of a load position and a work position, male protrusion upon said rack insert in close fit re- wherein manufactured configurations of said lo- 55 lation to assist in properly aligning said rack insert cating key and said first and second locating key upon said carriage in at least one of a load position recesses together comprise the primary engag- and a work position. ing components and surfaces for properly align- Item 6. A spline rolling rack assembly according to

8 15 EP 3 246 106 A2 16 item 5, wherein said rack insert further comprises ing surface with a series of feature-forming sur- inner and outer datum surfaces whose manufac- faces formed thereupon for cold-forming exter- tured configurations are prepared to precision toler- nal surface configurations upon a metal work- ances which in turn operate to enhance precision piece, said rack insert operable for being re- tolerances in the location of said feature-forming sur- 5 moved from, and secured upon, said carriage faces when said rack insert is in said work position. within said machine without removing said car- Item 7. A spline rolling rack assembly according to riage from within said machine; item 1, wherein manufactured configurations of said a locating key operable for being disposed be- locating key and said first and second locating key tween a first locating key recess formed within recesses are prepared to precision tolerances which 10 said rack insert and a second locating key re- in turn operate to enhance precision tolerances in cess formed within said carriage for properly the location of said feature-forming surfaces when aligning said rack insert upon said carriage in at said rack insert is in said work position. least one of a load position and a work position, Item 8. A spline rolling rack assembly according to wherein manufactured configurations of said lo- item 1, wherein said rack insert is designed for a15 cating key and said first and second locating key single use and is intended for disposal after said recesses together comprise the primary engag- working surface becomes worn. ing components and surfaces for properly align- Item 9. A spline rolling rack assembly according to ing said rack insert upon said carriage in at least item 1, wherein said locating key is secured to said one of a load position and a work position; and carriage by a locating key bolt. 20 a plurality of clamping assemblies disposed at Item 10. A spline rolling rack assembly according to spaced apart locations longitudinally within said item 1, wherein said rack insert and said carriage carriage, each clamping assembly operable for each include load alignment indicia on correspond- releasably contacting said rack insert in a pres- ing surfaces for indicating when the rack insert and surized manner for securing said rack insert in the carriage are aligned in a load position, prior to 25 afixed workposition upon said carriage, wherein slidingthe rack insert longitudinallyupon the carriage each clamping assembly is operable for being into a work position. adjusted between a released unclamped condi- Item 11. A spline rolling rack assembly according to tion and an engaged clamped condition. item 1, wherein said rack insert comprises at least one height location datum in contact with the carriage 30 Item 15. A spline rolling rack assembly for cold-form- during operation, whose manufactured configuration ing external surface configurations upon a metal is each prepared to precision tolerances which in workpiece, comprising: turn operate to enhance precision tolerances in the location of said feature-forming surfaces when said a durable carriage operable for being fixedly se- rack insert is in said work position. 35 cured upon a reciprocating slide assembly with- Item 12. A spline rolling rack assembly according to in a machine for forming external surface con- item 11, wherein said rack insert comprises inner figurations upon said metal workpiece, said car- and outer height location datums which are mounted riage having a mounting surface, said carriage upon, and correspond to, inner and outer datum rails operable for sliding in reciprocating relation to- formed upon the carriage. 40 gether with rotation of the workpiece; Item 13. A spline rolling rack assembly according to a perishable rack insert operable for being re- item 1 , wherein said external surface configurations movably secured upon said mounting surface formed upon a metal workpiece are in the form of of said carriage, said rack insert having a work- splines. ing surface with a series of feature-forming sur- Item 14. A spline rolling rack assembly for cold-form- 45 faces formed thereupon for cold-forming exter- ing external surface configurations upon a metal nal surface configurations upon a metal work- workpiece, comprising: piece, said rack insert operable for being re- moved from, and secured upon, said carriage a durable carriage operable for being fixedly se- within said machine without removing said car- cured upon a reciprocating slide assembly with- 50 riage from within said machine; and in a machine for forming external surface con- a plurality of clamping assemblies disposed at figurations upon said metal workpiece, said car- spaced apart locations longitudinally within said riage having a mounting surface, said carriage carriage, each clamping assembly operable for operable for sliding in reciprocating relation to- releasably contacting said rack insert in a pres- gether with rotation of the workpiece; 55 surized manner for securing said rack insert in a perishable rack insert operable for being re- afixed workposition upon said carriage, wherein movably secured upon said mounting surface each clamping assembly is operable for being of said carriage, said rack insert having a work- adjusted between a released unclamped condi-

9 17 EP 3 246 106 A2 18

tion and an engaged clamped condition. recess to engaging a small radius recess forming part of said clamping assembly recess in said rack Item 16. A method for preparing a spline rolling rack insert. assembly for cold- forming external surface config- Item 20. The method for preparing a spline rolling urations upon a metal workpiece comprising the5 rack assembly according to item 19, wherein the step steps of: of securing said at least one clamping assembly into a clamped condition between said carriage and said providing a durable carriage fixedly secured up- rack insert comprises securing said clamp pin on a reciprocating slide assembly within a ma- against said small radius recess. chine for forming external surface configurations 10 Item 21 . The method for preparing a spline rolling upon said metal workpiece; rack assembly according to item 16, wherein said providing a perishable rack insert operable for step of actuating a locating assembly disposed upon being removably secured upon a mounting sur- said carriage to engage said rack insert comprises face of said carriage; causing a lock pin to move from a first load position positioning said rack insert upon said mounting 15 to a second work-unclamped position and subse- surface of said carriage, so as to engage a lo- quently to a third work-clamped position between cating key secured upon said carriage with a said carriage and said rack insert. locating key recess disposed within said rack Item 22. A spline rolling rack assembly for cold-form- insert, to engage a locating assembly disposed ing external surface configurations upon a metal upon said carriage with a locating assembly re- 20 workpiece, comprising: cess disposed within said rack insert, and also to engage at least one clamping assembly dis- a durable carriage operable for being fixedly se- posed upon said carriage with a clamping as- cured upon a reciprocating slide assembly with- sembly recess disposed within said rack insert; in a machine for forming external surface con- actuating said locating assembly to move said 25 figurations upon said metal workpiece, said car- rack insert longitudinally relative to said carriage riage having a mounting surface, said carriage into a working position, to engage said locating operable for sliding in reciprocating relation to- key against a primary stop surface forming part gether with rotation of the workpiece; and of said locating key recess, and also to place a perishable rack insert operable for being re- said clamping assembly in a configuration to be 30 movably secured upon said mounting surface secured into a clamped condition; and of said carriage, said rack insert having a work- securing said at least one clamping assembly ing surface with a series of feature-forming sur- into a clamped condition between said carriage faces formed thereupon for cold-forming exter- and said rack insert. nal surface configurations upon a metal work- 35 piece, said rack insert operable for being re- Item 17. The method for preparing a spline rolling moved from, and secured upon, said carriage rack assembly according to item 16, wherein the step within said machine without removing said car- of positioning said rack insert upon said mounting riage from within said machine. surface of said carriage comprises engaging a plu- rality of clamping assemblies disposed upon said 40 Item 23. A spline rolling rack assembly according to carriage with a plurality of clamping assembly re- item 22, wherein said rack insert is designed for a cesses disposed within said rack insert; and single use and is intended for disposal after said wherein the step of securing said at least one clamp- working surface becomes worn. ing assembly into a locked condition between said Item 24. A spline rolling rack assembly for cold-form- carriage and said rack insert comprises securing a 45 ing external surface configurations upon a metal plurality of clamping assemblies into a locked con- workpiece, comprising: dition between said carriage and said rack insert. Item 18. The method for preparing a spline rolling a durable carriage operable for being fixedly se- rack assembly according to item 16, wherein the step cured upon a reciprocating slide assembly with- of positioning said rack insert upon said mounting 50 in a machine for forming external surface con- surface of said carriage causes a clamp pin protrud- figurations upon said metal workpiece, said car- ing from said carriage to engage a large radius re- riage having a mounting surface, said carriage cess forming part of said clamping assembly recess operable for sliding in reciprocating relation to- in said rack insert. gether with rotation of the workpiece; and Item 19. The method for preparing a spline rolling 55 a perishable rack insert operable for being re- rack assembly according to item 18, wherein the step movably secured upon said mounting surface of actuating said locating assembly causes said of said carriage, said rack insert having a work- clamp pin to switch from engaging said large radius ing surface with a series of feature-forming sur-

10 19 EP 3 246 106 A2 20

faces formed thereupon for cold-forming exter- face configurations upon a metal workpiece and nal surface configurations upon a metal work- a locking bearing surface, said rack insert oper- piece; able for being removed from, and secured upon, wherein said rack insert is designed for a single said carriage within said machine without re- use and is intended for disposal after said work- 5 moving said carriage from within said machine; ing surface becomes worn. a locating key operable for being disposed be- tween a first locating key recess formed within Item 25. A perishable rack insert operable for use as said rack insert and a second locating key re- part of a spline rolling rack assembly for cold-forming cess formed within said carriage for properly external surface configurations upon a metal work- 10 aligning said rack insert upon said carriage in at piece; least one of a load position and a work position, said rack insert having a working surface with a se- wherein manufactured configurations of said lo- ries of feature-forming surfaces formed thereupon cating key and said first and second locating key for cold-forming external surface configurations up- recesses together comprise the primary engag- on said metal workpiece; and 15 ing components and surfaces for properly align- said rack insert operable for being removably se- ing said rack insert upon said carriage in at least cured upon a durable carriage fixedly secured upon one of a load position and a work position, and a reciprocating slide assembly within a machine for wherein said locating key is secured to said car- forming external surface configurations upon said riage; metal workpiece, without removing said carriage20 a locating assembly operable for being disposed from within said machine. upon said carriage in movable relation between Item 26. A method for preparing a spline rolling rack a first position corresponding to a loading posi- assembly for cold- forming external surface config- tion of said rack insert upon said carriage and a urations upon a metal workpiece comprising the second position corresponding to a work posi- steps of: 25 tion of said rack insert upon said carriage, said locating assembly also operable for engaging a providing a durable carriage fixedly secured up- recess within said rack insert, wherein move- on a reciprocating slide assembly within a ma- ment of said locating assembly from said first chine for forming external surface configurations position to said second position engages said upon said metal workpiece; 30 locating assembly with said recess within said providing a perishable rack insert operable for rack insert to assist in properly aligning said rack being removably secured upon a mounting sur- insert upon said carriage in at least one of a load face of said carriage; position and a work position, wherein said locat- positioning said rack insert upon said mounting ing assembly comprises a lock pin attached to surface of said carriage; and 35 a lock shaft rotatably disposed within said car- securing said rack insert upon said mounting riage and capable of being rotated between a surface of said carriage without removing said first position corresponding to a load position of carriage from within said machine. said rack insert upon said carriage and a second position where the locking shaft engages a ta- 40 pered surface of the insert corresponding to a Claims work position of said rack insert upon said car- riage; and 1. A spline rolling rack assembly for cold-forming ex- a plurality of clamping assemblies disposed at ternal surface configurations upon a metal work- spaced apart locations longitudinally within said piece, comprising: 45 carriage, each clamping assembly having a translatable locking member with an annular en- a durable carriage operable for being fixedly se- gagement surface configured to engage the cured upon a reciprocating slide assembly with- locking bearing surface of the rack insert, the in a machine for forming external surface con- translatable locking member having a shaft de- figurations upon said metal workpiece, said car- 50 fining a cam following surface, said clamping as- riage having a mounting surface, said carriage semblies each having a rotatable member dis- operable for sliding in relation together with ro- posed generally perpendicular to the shaft and tation of the workpiece; having a cam configured to engage the cam fol- a perishable rack insert operable for being re- lowing surface upon rotation of the rotatable movably secured upon said mounting surface 55 member in a first direction, the translatable of said carriage, said rack insert having a work- member being operable for releasably contact- ing surface with a series of feature-forming sur- ing said rack insert in a pressurized manner for faces formed thereupon for forming external sur- securing said rack insert in a clamped work po-

11 21 EP 3 246 106 A2 22

sition upon said carriage, wherein each clamp- riage are aligned in a load position. ing assembly is operable for being adjusted be- tween a released unclamped condition and an 10. A spline rolling rack assembly according to claim 1, engaged clamped condition, wherein said locat- wherein said rack insert comprises at least one ing assembly comprises a lock member at-5 height location datum in contact with the carriage tached to a lock shaft rotatably disposed within during operation. said carriage and capable of being rotated be- tween a first position corresponding to a load 11. A spline rolling rack assembly according to claim 10, position of said rack insert upon said carriage wherein said rack insert comprises inner and outer and a second position corresponding to a work 10 height location datums which are mounted upon, and position of said rack insert upon said carriage. correspond to, inner and outer datum rails formed upon the carriage. 2. A spline rolling rack assembly according to claim 1, wherein each clamping assembly comprises a sur- 12. A spline rolling rack assembly according to claim 1, face disposed within said carriage and operable for 15 wherein said external surface configurations formed engaging a clamp pin which forms part of the clamp- upon a metal workpiece are in the form of splines. ing. 13. A spline rolling rack assembly for cold-forming ex- 3. A spline rolling rack assembly according to claim 2, ternal surface configurations upon a metal work- wherein each clamping assembly is operable for en- 20 piece, comprising: gaging a recess within the rack insert, and wherein adjustment of said clamping assembly from a re- a durable carriage operable for being fixedly se- leased unclamped condition to an engaged clamped cured upon a slide assembly within a machine condition operates to engage the clamp pin forming for forming external surface configurations upon part of the clamping assembly against said recess 25 said metal workpiece, said carriage having a within said rack insert. mounting surface, said carriage operable for sliding in reciprocating relation together with ro- 4. A spline rolling rack assembly according to claim 1, tation of the workpiece; wherein said carriage includes longitudinally dis- a perishable rack insert operable for being se- posed inner and outer datum rails for engaging a 30 lectively secured upon said mounting surface of member upon said rack insert in close fit relation to said carriage, said rack insert having a working assist in properly aligning said rack insert upon said surface with a series of feature-forming surfaces carriage in at least one of a load position and a work formed thereon for cold-forming external sur- position. face configurations upon a metal workpiece, 35 said rack insert defining a coupling aperture 5. A spline rolling rack assembly according to claim 1, holding an insert bearing plate that defines a wherein said rack insert further comprises an inner bearing surface, said rack insert operable for be- datum surface locations said feature-forming surfac- ing removed from, and secured upon, said car- es when said rack insert is in said work position. riage within said machine without removing said 40 carriage from within said machine; 6. A spline rolling rack assembly according to claim 1, a locating key operable for being disposed be- wherein said locating key and said first and second tween a first locating key recess formed within locating key recesses operate to enhance the loca- said rack insert and a second locating key re- tion of said feature-forming surfaces when said rack cess formed within said carriage for properly insert is in said work position. 45 aligning said rack insert upon said carriage in at least one of a load position and a work position, 7. A spline rolling rack assembly according to claim 1, wherein manufactured configurations of said lo- wherein said rack insert selectively wears and is in- cating key and said first and second locating key tended for disposal after said working surface be- recesses together comprise the primary engag- comes worn. 50 ing components and surfaces for properly align- ing said rack insert upon said carriage in at least 8. A spline rolling rack assembly according to claim 1, one of a load position and a work position; and wherein said locating key is secured to said carriage. a plurality of clamping assemblies disposed on said carriage, each clamping assembly having 9. A spline rolling rack assembly according to claim 1, 55 a translatable locking member with an engage- wherein said rack insert and said carriage each in- ment surface configured to engaged the ramped clude load alignment indicia on corresponding sur- bearing surface of the rack insert, the translat- faces for indicating when the rack insert and the car- able locking member having a shaft defining a

12 23 EP 3 246 106 A2 24

cam following surface, said clamping assem- upon said metal workpiece; blies each having a member disposed generally providing a perishable rack insert defining a perpendicular to the shaft and having a cam con- clamping assembly having a selectively enga- figured to engage the ramped bearing surface gable bearing surface operable for being remov- upon movement of the rotatable member in a 5 ably secured upon a mounting surface of said first direction, the translatable member being carriage; each clamping assembly operable for releasa- disposing a locking member defining a bearing bly contacting said rack insert in a compressive surface adjacent the selectively engagable manner for securing said rack insert in a fixed bearing surface; work position in said carriage. 10 positioning said rack insert upon said mounting surface of said carriage, so as to engage a lo- 14. A spline rolling rack assembly for cold-forming ex- cating key secured upon said carriage with a ternal surface configurations upon a metal work- locating key recess disposed within said rack piece, comprising: insert, to engage a locating assembly disposed 15 upon said carriage with a locating assembly re- a durable carriage operable for being fixedly se- cess disposed within said rack insert, and also cured upon a reciprocating slide assembly with- to engage at least one clamping assembly dis- in a machine for forming external surface con- posed upon said carriage with the selectively figurations upon said metal workpiece, said car- engagable bearing surface, wherein said locat- riage operable for sliding in reciprocating rela- 20 ing assembly comprises a lock pin attached to tion together with rotation of the workpiece; a lock shaft rotatably disposed within said car- a perishable rack insert operable for being re- riage and capable of being rotated between a movably secured upon said carriage, said rack first position corresponding to a load position of insert having a working surface with a series of said rack insert upon said carriage and a second feature-forming surfaces formed thereupon for 25 position where the locking shaft engages a ta- cold-forming external surface configurations up- pered surface of the insert corresponding to a on a metal workpiece, said rack insert defining work position of said rack insert upon said car- a coupling bearing surface, said perishable rack riage; insert being operable for being removed from, actuating said locating assembly to move said and secured upon, said carriage within said ma- 30 rack insert longitudinally relative to said carriage chine without removing said carriage from within into a working position, to engage said locating said machine; and key against a primary stop surface forming part a plurality of clamping assemblies having a se- of said locating key recess, and also to place lectively rotatably translatable member with a said clamping assembly in a configuration to be ramped annular engagement surface config- 35 secured into a clamped condition; and ured to engage the coupling bearing surface of securing said at least one clamping assembly the rack insert, the selectively translatable mem- into a clamped condition between said carriage ber having a cam following surface, said clamp- and said rack insert. ing assemblies each having a movable member disposed generally perpendicular to the shaft 40 16. The method for preparing a spline rolling rack as- and having a cam configured to engage the cam sembly according to claim 15, wherein the step of following surface upon translation of the trans- positioning said rack insert upon said carriage com- latable member in a first direction, the selectively prises engaging a plurality of clamping assemblies translatable member being operable for releas- between said carriage and said rack insert. ably contacting said rack insert in a compressive 45 manner for securing said rack insert in a fixed 17. The method for preparing a spline rolling rack as- work position upon said carriage, wherein each sembly according to claim 15, wherein the step of clamping assembly is operable for being adjust- positioning said rack insert upon said carriage caus- ed between a released unclamped condition es a clamp pin protruding from said carriage to en- and an engaged clamped condition. 50 gage a large radius recess forming part of said clamping assembly recess in said rack insert. 15. A method for preparing a spline rolling rack assembly for cold-forming external surface configurations up- 18. The method for preparing a spline rolling rack as- on a metal workpiece comprising the steps of: sembly according to claim 17, wherein the step of 55 actuating said locating assembly causes said clamp providing a durable carriage fixedly secured up- pin to switch from engaging said large radius recess on a reciprocating slide assembly within a ma- to engaging a small radius recess forming part of chine for forming external surface configurations said clamping assembly recess in said rack insert.

13 25 EP 3 246 106 A2 26

19. The method for preparing a spline rolling rack as- sembly according to claim 18, further comprising se- curing said clamp pin against said small radius re- cess. 5 20. The method for preparing a spline rolling rack as- sembly according to claim 15, further comprising causing a lock pin to move from a first load position to a second work-unclamped position and subse- quently to a third work-clamped position between 10 said carriage and said rack insert.

21. A perishable rack insert operable for use as part of a spline rolling rack assembly for cold-forming exter- nal surface configurations upon a metal workpiece, 15 said rack insert comprising:

a working surface with a series of feature-form- ing surfaces formed thereupon for cold-forming external surface configurations upon said metal 20 workpiece; and said rack insert defining an aperture having a ramped bearing surface operable for being re- movably secured upon a durable carriage fixed- ly secured upon a reciprocating slide assembly 25 within a machine for forming external surface configurations upon said metal workpiece, with- out removing said carriage from within said ma- chine. 30 22. A method for preparing a spline rolling rack assembly for cold-forming external surface configurations up- on a metal workpiece comprising the steps of:

providing a durable carriage support having a 35 plurality of coupling mechanisms, said durable carriage support being fixedly secured upon a reciprocating slide assembly within a means for forming external surface configurations upon said metal workpiece; 40 providing a perishable rack insert operable for being removably secured upon a mounting sur- face of said carriage, said perishable rack insert defining an annular ramped coupling bearing surface; 45 positioning said rack insert upon said mounting surface of said carriage; securing said rack insert to the coupling mech- anism upon said mounting surface of said car- riage without removing said carriage from within 50 said machine; and translating the coupling mechanism to engage the coupling bearing sur- face of the rack insert.

55

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REFERENCES CITED IN THE DESCRIPTION

This list of references cited by the applicant is for the reader’s convenience only. It does not form part of the European patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be excluded and the EPO disclaims all liability in this regard.

Patent documents cited in the description

• EP 13793260 A [0001]

20