A forming process for stepped tooth-shaped parts

Abstract

The present invention relates to the field of mechanical processing technology, and specifically to a forming process for stepped and non-through toothed parts, in which the parts are subjected to three roll forming processes, in which the tooth roots, tooth tops and the entire tooth portion of the parts are processed in sequence, and then the stepped teeth and non-through teeth are processed. A roller forming structure with supplementary process characteristics obtained by simulation calculation and a final deep drawing and shaping structure are used to achieve stamping forming of stepped and non-through toothed parts. The manufacturing process is relatively simple, and the processing requirements for functional components are reduced, so that the manufacturing cost is lower than the existing process structure, and the overall service life is greatly improved.

Description

Technical Field

[0001] The invention relates to the technical field of mechanical processing, in particular to a forming process of a stepped non-through toothed part. Background Art

[0002] As the world increasingly focuses on the importance of developing advanced manufacturing technologies, the level of domestic mechanical parts processing and manufacturing is gradually improving. Stamping processes are gaining increasing share in the automotive parts manufacturing sector due to their relatively simple operation, ease of mechanization and automation, high production efficiency, high material utilization, and relatively stable dimensions and good interchangeability of parts.

[0003] Traditional stamping processes are categorized by process: 1. Fracture separation processes, such as blanking, punching, trimming, and cutting; and 2. Plastic forming processes, such as bending, drawing, expanding, flanging, shrinking, and curling. With the current demand for efficiency, high integration, and high stability in product process development, as well as the need for maximum cost savings, strengthening simulation analysis in the early stages of mold development, improving mold manufacturing accuracy, extending mold life, and optimizing mold structure and function have become the current trends in mold technology development.

[0004] Currently, through-tooth stamping is increasingly being used in stamping, and the forming process is becoming increasingly mature. The main forming methods generally include deep drawing, side shaping, and roll forming. However, with the increasing requirements for product processing, products with non-through teeth and stepped teeth have also emerged. Currently, the main forming structure for stamping parts with stepped and non-through teeth is semi-shaped wheel roll forming. However, this forming method has relatively complex mold structures and high manufacturing costs. In addition, due to the high stresses on some functional components, the materials used, heat treatment processes, processing dimensions, and process requirements are very strict, resulting in a relatively short service life. Summary of the Invention

[0005] The purpose of the present invention is to provide a forming process for stepped and non-through tooth parts, aiming to solve the technical problems in the prior art that the forming structure of stepped and non-through tooth forming stamping parts is relatively complex, the manufacturing cost is high, and the service life of individual functional parts is relatively short due to the large force they are subjected to.

[0006] To achieve the above object, the present invention provides a forming process for a stepped non-through toothed part, comprising the following steps:

[0007] The parts are rolled three times, processing the tooth root, tooth top and the entire tooth part in sequence;

[0008] The parts that have been rolled three times are drawn for the first time to process stepped teeth;

[0009] The part is drawn a second time without teeth.

[0010] Among them, in the steps of rolling the parts three times and processing the tooth root, tooth top and the entire tooth part of the parts in sequence:

[0011] The three-stage roll forming process is performed using gear cores, forming rollers and roller fixing groups of different sizes.

[0012] The step of rolling the part three times to sequentially process the tooth root, tooth top and the entire tooth portion of the part comprises:

[0013] The first step of roll forming is to pre-form the tooth root of the part. The forming tooth profile mold core is a through-tooth structure. The corresponding supplementary process feature height is H1, which is smaller than the feature height of the step tooth profile of the part.

[0014] The second step of roll forming is to pre-form the top of the tooth of the part. The corresponding forming roller does not contact the root part of the tooth. The height of the corresponding supplementary process feature is H2, which is greater than H1.

[0015] The third step of roll forming is the tooth finishing process. The forming roller forms the entire tooth profile. The corresponding supplementary process feature height is H3, which is the same as the finished step tooth profile height, and H3 is greater than H1.

[0016] Among them, in the step of processing stepped teeth by the first deep drawing of the parts that have been rolled three times:

[0017] The component is drawn for the first time using the tooth-shaped die core and the stepped tooth outer forming ring.

[0018] Among them, in the step of drawing the parts for the second time and processing the non-through teeth:

[0019] The part is drawn a second time through the tooth-shaped die core and the non-toothed outer shaping ring.

[0020] The present invention provides a forming process for stepped tooth-shaped parts, which adopts a roller forming structure with supplementary process characteristics obtained by simulation calculation and a final deep drawing and shaping structure, thereby realizing the stamping forming of stepped tooth-shaped parts. The manufacturing process is relatively simple, and the processing requirements for functional components are reduced, so that the manufacturing cost is lower than the existing process structure, and the overall service life is greatly improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0022] Figure 1 It is a schematic diagram of the tooth profile of a stepped non-through tooth part provided by the present invention.

[0023] Figure 2 It is a schematic diagram of the roll forming structure of the roller group provided by the present invention.

[0024] Figure 3 It is a schematic cross-sectional view of the rolling one-step forming structure provided by the present invention.

[0025] Figure 4 It is a schematic cross-sectional view of the rolling two-step forming structure provided by the present invention.

[0026] Figure 5 It is a schematic cross-sectional view of the three-step rolling forming structure provided by the present invention.

[0027] Figure 6 It is a schematic cross-sectional view of the step drawing sequence structure provided by the present invention.

[0028] Figure 7 It is a schematic diagram of the terminal blind tooth shaping structure provided by the present invention.

[0029] 1-gear mold core, 2-forming roller, 3-roller fixing group, 4-one-step forming tooth mold core, 5-forming roller, 6-two-step forming tooth mold core, 7-two-step forming roller, 8-three-step forming tooth mold core, 9-three-step forming roller, 10-forming tooth mold core, 11-step tooth forming outer ring, 12-inner forming tooth mold core, 13-outer blind tooth external shaping ring. DETAILED DESCRIPTION

[0030] The following describes embodiments of the present invention in detail, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and are not to be construed as limiting the present invention.

[0031] See also Figures 1 to 7 The present invention provides a forming process for a stepped non-through toothed part, comprising the following steps:

[0032] S1: The part is rolled three times, processing the tooth root, tooth top and the entire tooth part in sequence;

[0033] S2: The parts that have been rolled three times are subjected to the first deep drawing to process the stepped teeth;

[0034] S3: The part is drawn a second time without teeth.

[0035] Among them, in step S1: three rolling forming processes are respectively performed using gear mold cores 1, forming rollers 2 and roller fixing groups 3 of different sizes. The first step of rolling forming is the pre-forming of the tooth root of the part. The forming tooth mold core is a through-tooth structure. Only when the position is given as a supplementary process feature, the height of the mold core supplementary process feature should be lower than the characteristic height of the stepped tooth profile of the final formed part. It is marked as H1 (such as Figure 3 ), during forming, the one-step forming roller 5 is used to roll the part's tooth root material according to the contour shape of the one-step forming tooth profile mold core 4. In addition, the rolling height (MH1) of this step of rolling forming needs to be incompletely rolled through the part's tooth profile area; the second step of rolling forming mainly performs pre-forming on the top of the part's teeth, and the two-step forming roller 7 generally only performs contour pre-forming on the top of the tooth in the tooth profile area, and basically has no contact with the part material at the tooth root. However, since the entire part tooth material will flow upward as shown in the figure along with the forming roller during rolling forming, the design of the supplementary process feature height (H2) of the two-step forming tooth profile mold core 6 needs to be greater than the supplementary process feature height (H1) of the first step forming tooth profile mold core. In addition, because the material of the non-toothed area on the edge generally needs to be thinned, the rolling height (MH2) of most second-step rolling forming needs to be completely rolled through the entire tooth area of ​​the part; the third step of rolling forming is the tooth fine forming process, and the three-step forming roller 9 forms the entire tooth profile. In this step, the overall contour size of the stepped tooth area needs to be basically completed, so the supplementary process feature height (H3) of the three-step forming tooth core 8 needs to be basically consistent with the height of the finished stepped tooth profile. In order to facilitate the forming of the non-toothed area on the edge, the forming height (MH3) of the forming roller in this step only needs to meet the height of the effective tooth profile of the part. Usually, the height relationship of the supplementary process feature of the three-step forming mold core for the stepped tooth profile is H3>H2>H1, and the rolling height relationship of the three-step forming roller for the non-toothed tooth profile is MH2>MH3>MH1.

[0036] In step S2: After the part tooth profile is formed by three-step rolling, the step teeth and the non-through tooth profile area need to be refined by a simple deep drawing structure. First, the inner side of the step tooth profile is formed by using the forming tooth profile mold core 10 with the same characteristic size as the third step forming punch and the outer side of the step tooth forming outer ring 11 to complete the forming of the step teeth through the traditional deep drawing process.

[0037] In step S3: the forming of the non-toothed area is also completed through the deep drawing process, but the inner forming tooth core 12 and the outer non-toothed outer shaping ring 13 need to be designed according to the characteristic contour of the non-toothed area of ​​the part; this manufacturing process is relatively simple, and the processing requirements for functional components are reduced, so the manufacturing cost is lower than the existing process structure, and the overall service life is greatly improved.

[0038] The above disclosure is only a preferred embodiment of the present invention, and certainly cannot be used to limit the scope of the rights of the present invention. Ordinary technicians in this field can understand that all or part of the processes of the above embodiment and equivalent changes made in accordance with the claims of the present invention are still within the scope of the invention.

Claims

1. A forming process for stepped toothed parts, characterized in that: The steps include: The parts are rolled three times, processing the tooth root, tooth top and the entire tooth part in sequence; The parts that have been rolled three times are drawn for the first time to process stepped teeth; The parts are drawn a second time without any teeth; In the steps of rolling the part three times, processing the tooth root, tooth top and the entire tooth part in sequence: The three-stage roll forming is processed using toothed mold cores, forming rollers and roller fixing groups of different sizes.

2. A forming process for a stepped non-through toothed part according to claim 1, characterized in that: The steps of rolling the part three times to sequentially process the tooth root, tooth top and the entire tooth portion of the part include: The first step of roll forming is to pre-form the tooth root of the part. The forming tooth profile mold core is a through-tooth structure. The corresponding supplementary process feature height is H1, which is smaller than the feature height of the step tooth profile of the part. The second step of roll forming is to preform the top of the tooth of the part. The corresponding forming roller does not contact the root part of the tooth. The height of the supplementary process feature of the corresponding forming tooth mold core is H2, which is greater than H1. The third step of rolling forming is the tooth fine forming process. The forming roller forms the entire tooth. The height of the corresponding forming tooth mold core's supplementary process feature is H3. H3 is the same as the height of the finished stepped tooth profile, and H3 is greater than H1.

3. A forming process for a stepped non-through toothed part according to claim 2, characterized in that: During the first deep drawing of a part that has been rolled three times, and the step teeth are processed: The part is drawn for the first time by forming the tooth-shaped die core and the stepped tooth-shaped outer ring.

4. A forming process for a stepped non-through toothed part according to claim 3, characterized in that: In the step of drawing the part for the second time and processing the non-through teeth: The part is drawn a second time through the tooth-shaped die core and the non-toothed outer shaping ring.

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