Method for roll-forming disk carriers or the like and the associated profile roller set

A profile roller tool for roll-forming a disk carrier from a sheet metal part having toothing comprising inner and outer teeth, comprising:

• a plurality of cassettes spaced equidistantly on a circumference of a roll-forming tool, each of said plurality of cassettes having a plurality of profile rollers arranged in an interior of each of the plurality of cassettes, an outer circumference of the plurality of profile rollers positioned within the plurality of cassettes so as to roll relative to the sheet metal part to form the toothing on the disk carrier,
• wherein the plurality of profile rollers have a given forming depth with respect to the sheet metal part to create a narrow, peripheral, self-contained, unformed bridge remaining between an inner diameter and an outer diameter of the toothing, said bridge defining a hoop band cylinder that is integrated into the toothing to increase engine-speed strength of the disk carrier, said hoop band cylinder having an axial length approximately equals an axial length of the disk carrier,
• wherein the plurality of profile rollers are configured to form the toothing so as to comprise an outer profile which is formed by radially inward-facing profile sections, which steadily transitions to a radially outward-facing profile sections,
• wherein the plurality of profile rollers are further configured to form the toothing so as to comprise an inner profile of the disk carrier, the inner profile comprising radially inward-facing teeth, which steadily and repeatedly transitions to teeth heads with larger diameters at equidistantly arranged locations around an entire circumference of the disk carrier,
• wherein the plurality of profile rollers are further configured to form the hoop band cylinder defined between the outer profile and the inner profile so as to extend around the entire circumference of the disk carrier.

A method for spin-forming a disk carrier from a sheet metal part to form toothing having inner and outer teeth, comprising:

• arranging a plurality of cassettes equidistantly on a circumference of a tool, each of said plurality of cassettes having an interior in which spinning tools are arranged and profile elements disposed at a front surface of the spinning tools,
• setting a forming depth of the profile elements at a given position to create, in accordance with the given position, a narrow, peripheral, self-contained, unformed bridge that remains between an inner diameter and an outer diameter of the toothing of the disk carrier, said bridge defines a hoop band cylinder that is integrated into the toothing to increase engine-speed strength of the disk carriers, and said hoop band cylinder having an axial length approximately equals an axial length of the disk carrier, and
• shaping the disk carrier to be formed with an outer circumference of the profile elements to form the toothing and the hoop band cylinder on the disk carrier, the shaping comprising:
• forming radially inward-facing profile sections, which steadily transition to radially outward-facing profile sections, to form an outer profile of the disk carrier comprising the toothing,
• forming the toothing comprising an inner profile of the disk carrier, the toothing comprising radially inward-facing teeth, which steadily and repeatedly transition to teeth heads with larger diameters at equidistantly arranged locations around an entire circumference of the disk carrier,
• forming the hoop band cylinder between the two profile sections of the outer profile and the inner profile, and the two profile sections of the radially outward-facing profile section and the tooth head so as to extend around the entire circumference of the disk carrier.