Vertical non-cutting fine-net gear forming device and inserting and rolling composite forming process of vertical non-cutting fine-net gear forming device

Abstract

The invention discloses a vertical non-cutting fine net forming device for a gear and an inserting and rolling composite forming process of the vertical non-cutting fine net forming device, belongs to the technical field of gear forming, solves the technical problem that a metal flow line is cut off in the plastic deformation process of the gear, and adopts the technical scheme that the vertical non-cutting fine net forming device comprises a main rack, a driving motor, a speed reducer and two groups of fine net forming devices, the driving motor and the speed reducer are both arranged in the main machine frame, and the fine net forming device comprises a retaining ring, a locking nut, a fine net forming tooth roller, a mandrel moving frame, a support and a feeding oil cylinder. An initial guiding section, a biting section, a material distributing section, a tooth shape pre-forming section, an involute forming section and a tooth shape finishing section are sequentially and coaxially arranged from the head portion to the tail portion of the fine forming tooth roller according to the forming process, and the multiple sections of forming teeth are equal in tooth number and are sequentially connected. When the gear is subjected to insert grinding composite forming, a complete metal flow line is formed in the gear plastic deformation process, the strength, corrosion resistance and wear resistance of the gear tooth surface are improved, and the service life of the gear is prolonged.

Description

Technical Field

[0001] The invention belongs to the technical field of gear forming, and specifically relates to a device for vertical non-cutting precision forming of gears and an insert-rolling composite forming process thereof. Background Art

[0002] Gears and gear rings are common mechanical transmission parts, which are widely used in industrial production in various fields. The current gear manufacturing process is as follows: forging (or ring rolling) to form ring blanks, initial turning of blanks, and mechanical processing of gear shaping (or gear hobbing) to form tooth profiles. Not only is the process route lengthy, the manufacturing cycle is long, and large-scale processing equipment is seriously occupied; at the same time, because the tooth profile is formed by mechanical processing, the plastically deformed metal streamlines are cut off, resulting in fiber leakage, making the tooth surface more susceptible to corrosion, wear, surface shedding, etc., and easily causing the tooth root to break, etc., which ultimately leads to a serious reduction in the service life and service cycle of the gear. How to form a full-fiber streamline tooth profile and increase the service life of the gear has become an urgent problem to be solved. Summary of the invention

[0003] The main purpose of the present invention is to overcome the deficiencies in the prior art and solve the technical problem of metal streamlines being cut off during the plastic deformation of gears. The present invention provides a device for vertical non-cutting precision forming of gears and its insertion and rolling composite forming process.

[0004] The present invention is achieved through the following technical solutions:

[0005] A vertical non-cutting, inserting and rolling composite precision forming device for gears, comprising a main frame, a driving motor, a reducer and two sets of precision forming devices, wherein: the upper end of the main frame is set in an open shape, a guide plate is covered at the open position of the upper end surface of the main frame, an axial hole is set in the middle of the guide plate, and long hole grooves are symmetrically set on both sides of the guide plate along the diameter direction;

[0006] The drive motor and the reducer are both arranged in the main frame, the drive motor is arranged in the horizontal direction, the rotor of the drive motor is connected to the power input shaft of the reducer, the power output shaft of the reducer is arranged vertically upward, the power output shaft of the reducer is fixedly connected to the lower end of the support sleeve, the upper end of the support sleeve passes through the shaft hole and extends to the outside of the main frame, the round blank is clamped on the upper part of the support sleeve, and a slewing bearing is arranged between the outer wall of the support sleeve and the shaft hole;

[0007] The precision forming device comprises a guard ring, a locking nut, a precision forming gear roller, a mandrel moving frame, a bracket and a feed cylinder. The guard ring is fixedly sleeved on the outside of the guide plate, and the upper end surface of the guard ring is higher than the upper surface of the guide plate. Two locking nuts are arranged opposite to each other along the diameter direction of the guard ring, and the locking nuts penetrate the guard ring. A plurality of pads are detachably arranged on the locking nuts on the inner side of the guard ring.

[0008] The mandrel moving frame is arranged in a C shape, and the two mandrel moving frames are movably mounted on the upper surface of the guide plate respectively, and the two mandrel moving frames are arranged relatively with respect to the axial direction of the round blank, and the edge of the round blank is located in the groove of the mandrel moving frame opening, and the locking nut drives the pad to press the outer wall of the web of the mandrel moving frame, and a plurality of pads are arranged according to the distance between the outer wall of the web of the mandrel moving frame and the inner wall of the guard ring, and the pad can ensure the relative distance between the mandrel moving frame and the guard ring is stable; the bracket is arranged above the mandrel moving frame, and the feed cylinder vertical It is installed straight downward on the bracket, the piston rod of the feed cylinder is fixedly connected to the upper end of the precision formed gear roller, the lower end of the precision formed gear roller passes through the bracket, the core shaft moving frame, the long hole groove from top to bottom and extends to the main frame, and forming teeth are arranged on the outer wall of the precision formed gear roller. The feed cylinder drives the precision formed gear roller to move downward along the axial direction. At the same time, the support sleeve drives the precision formed gear roller to rotate through the round blank. The precision formed gear roller is continuously or intermittently spirally fed downward to insert and grind the composite gear tooth shape on the outer cylindrical surface of the round blank.

[0009] Furthermore, the fine forming gear roller is configured as a plurality of long shaft parts with forming teeth, the plurality of forming teeth have an equal number of teeth and are connected in sequence, and the pitch circle Φ of each section on the fine forming gear roller 轴 The pitch circle of the gear after round blank processing is Φ 坯 Tangent, and at any moment the pitch circle Φ 轴 With the pitch circle Φ 坯 The linear speed at the point of tangency is equal: v 轴 =v 坯 ; At any time, the dividing circle Φ 轴 With the pitch circle Φ 坯 The ratio of the angular velocities at the point of tangency is equal to the inverse ratio of the pitch circle diameter:

[0010] From the head to the tail of the precision forming gear roller, the initial guide section, the biting section, the material dividing section, the tooth profile preforming section, the involute forming section and the tooth profile finishing section are coaxially arranged in sequence according to the forming process;

[0011] The initial guide segment is set to be cylindrical, and the length of the initial guide segment is not less than 1 / 2 of the height of the blank; in the initial state of the plug-roll composite forming, the outer cylindrical surface of the initial guide segment is tangent to the outer cylindrical surface of the round blank;

[0012] The biting section, the outer wall of the biting section is set as a conical surface, the small end face of the biting section is connected to the initial guide section, the outer wall of the biting section is provided with biting cone teeth, the taper of the biting cone teeth (i.e., the rapid biting angle) is α, 8°≤α≤15°; the driving roller in the present invention is a power input device for the "rolling ring forming" of the round billet, that is, the driving roller drives the round billet to rotate along the circumferential direction, when the biting section of the precision forming tooth roller is inserted into the round billet, the round billet drives the precision forming tooth roller to rotate around the axis direction, and at the same time, the precision forming tooth roller is downwardly "geared" to finally realize the "insertion" and "rolling" composite forming of the precision forming tooth roller;

[0013] In the gear insertion and rolling composite forming process, the rotation of the precision forming gear roller needs to match the rotation of the blank, so that the pitch circle always remains tangent and there can be no slipping relative movement. The rotation relationship is related to the number of teeth, module, and pitch circle size of the gear. The taper of the biting bevel tooth enables the biting section of the precision forming gear roller to quickly insert into the outer cylindrical surface of the round blank to achieve biting, thereby ensuring that there is no relative movement between the rotation of the forming mold and the rotation of the blank.

[0014] The material dividing section, the outer wall of the material dividing section is set as a conical surface, the small end surface of the material dividing section is connected to the large end surface of the biting section, and the material dividing cone teeth are arranged on the outer wall of the material dividing section, each material dividing cone tooth is respectively connected to the corresponding biting cone tooth, the taper of the material dividing cone tooth is β, 3°≤β≤10°, and β<α, and the ratio of the length of the generatrix of the biting section to the length of the generatrix of the material dividing section is not greater than 1 / 3;

[0015] After the bite section of the precision forming gear roller quickly bites into the outer cylindrical surface of the round billet, it enters the stable material distribution stage. The working principle of the material distribution stage is based on the billet making and pre-forging process of die forging to achieve further distribution of the billet metal. The taper of the material distribution cone is β (i.e., the insertion angle), which is a critical parameter and will directly affect the rolling force, die insertion force, and equipment operation stability.

[0016] The tooth profile preforming section, involute forming section and tooth profile finishing section are all arranged as spur gear shafts, the tooth profile preforming section is connected to the large end face of the dividing section, the number of teeth, module, addendum circle, root circle and base circle of the tooth profile preforming section, involute forming section and tooth profile finishing section are all the same, the tooth profile profile of the tooth profile preforming section is a trapezoidal profile, and the tooth profile profile of the involute forming section and the tooth profile finishing section is an involute profile; wherein:

[0017] The tooth profile preforming section is used to preform the entire forming tooth into a trapezoidal cross section along the height direction of the round blank, that is, the volume (or cross-sectional area) of the forming tooth pressed into the gear by the tooth profile preforming section of the precision forming gear roller is equal to the volume (or cross-sectional area) of the blank that is reversely squeezed into the tooth groove of the adjacent forming tooth;

[0018] The involute forming section is used to form the gear tooth profile from a trapezoidal cross-sectional profile to an involute cross-sectional profile;

[0019] The tooth profile finishing section finishes the tooth profile section to form an involute gear.

[0020] Furthermore, a positioning section is arranged at the front end of the initial guide section, the positioning section is arranged in a truncated cone shape, and the diameter of the large end of the positioning section is equal to the diameter of the initial guide section.

[0021] Furthermore, slide rails are respectively arranged on the upper surface of the guide plate and at the front and rear sides of the cushion block, and the cushion block reciprocates along the slide rails.

[0022] Furthermore, a magnetic suction cup or a vacuum suction cup is arranged on the upper end surface of the support sleeve, and the round blank is magnetically sucked on the magnetic suction cup or adsorbed on the working surface of the vacuum suction cup.

[0023] The insertion and rolling composite forming process of the gear without cutting and cleaning is carried out by using the above-mentioned device, which comprises the following steps:

[0024] S1. Initial guide: The round blank is mounted on the support sleeve, and the locking nut drives the pad and the mandrel moving frame to move toward one side of the round blank along the long hole groove set on the guide plate until the initial guide section of the fine forming gear roller presses the outer cylindrical surface of the round blank, and then several pads are inserted into the locking nut according to the distance between the web of the mandrel moving frame and the inner wall of the guard ring, and finally the locking nut is locked;

[0025] S2, biting: the feed cylinder and the drive motor are started at the same time, the drive motor drives the round blank to rotate through the reducer and the support sleeve, and the round blank drives the precision forming gear roller to rotate. At the same time, the feed cylinder drives the precision forming gear roller to move downward along the axis direction to the biting section, and the precision forming gear roller is continuously or intermittently fed downward in a spiral along the axis direction, and a tooth groove corresponding to the biting bevel tooth shape is formed on the outer cylindrical surface of the round blank;

[0026] S3, material division: the feed cylinder drives the fine forming gear roller to continue to move downward along the axis direction to the material division section, the drive motor keeps rotating at the speed in step S2, the fine forming gear roller continuously or intermittently spirally feeds downward along the axis direction, and forms tooth grooves corresponding to the tooth shape of the material division cone teeth on the outer cylindrical surface of the round blank;

[0027] S4, tooth profile preforming: the feed cylinder drives the fine forming gear roller to continue to move downward along the axis direction to the tooth profile preforming section, the drive motor keeps rotating at the speed in step S2, the fine forming gear roller is continuously or intermittently fed downward along the axis direction, and the tooth groove corresponding to the tooth profile of the forming tooth in the tooth profile preforming section is formed on the outer circumferential surface of the round blank;

[0028] S5, involute forming: the feed cylinder drives the fine forming gear roller to continue to move downward along the axis direction to the involute forming section, the drive motor keeps rotating at the speed in step S2, the fine forming gear roller is continuously or intermittently fed downward along the axis direction, and the tooth groove formed on the outer cylindrical surface of the round blank in step S4 is processed into an involute tooth groove;

[0029] S6, tooth shape finishing: the feed cylinder drives the finely formed gear roller to continue to move downward along the axis direction to the tooth shape finishing section, the drive motor keeps rotating at the speed in step S2, the finely formed gear roller is continuously or intermittently fed downward in a spiral along the axis direction, the tooth shape finishing section finishes the involute tooth groove formed on the outer cylindrical surface of the round blank in step S5, and the insertion and rolling composite non-cutting finely formed gear processing is completed;

[0030] S7, the driving motor stops working, and the feed cylinder drives the precision-formed gear roller to move upward along the axial direction until the precision-formed gear roller is separated from the precision-formed gear, and then the non-cutting precision-formed gear is removed from the supporting sleeve, and the above steps S1 to S6 are repeated to perform the next round blank insertion and rolling composite non-cutting precision forming process.

[0031] The beneficial effects of the present invention are as follows: from the head to the tail of the precision-formed gear roller, the following are coaxially arranged in sequence according to the forming process: the initial guide section, the biting section, the material dividing section, the tooth profile pre-forming section, the involute forming section and the tooth profile finishing section. A complete metal streamline is formed during the plastic deformation of the gear spur teeth, thereby improving the strength, corrosion resistance and wear resistance of the gear tooth surface and extending the service life of the gear. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 It is a schematic diagram of the main cross-sectional structure of the present invention;

[0033] Figure 2 It is a schematic diagram of the top view structure of the present invention;

[0034] Figure 3 This is a schematic diagram of the main structure of the precision formed gear roller;

[0035] Figure 4 for Figure 3 A schematic diagram of a local enlarged structure;

[0036] Figure 5 It is a tooth profile comparison diagram of the biting section, the material dividing section, the tooth profile pre-forming section, the involute forming section and the tooth profile finishing section; among which, Figure AA is Figure 3 The view in the AA direction, Figure BB is Figure 3 The view from the BB direction, Figure CC is Figure 3 View from CC direction, Figure DD is Figure 3 The view from the DD direction, Figure EE is Figure 3 View from the EE direction.

[0037] In the figure, 1 is a precision formed gear roller, 1-1 is an initial guide section, 1-2 is a bite section, 1-3 is a material dividing section, 1-4 is a tooth profile pre-forming section, 1-5 is an involute forming section, 1-6 is a tooth profile finishing section, 1-7 is a positioning section, 2 is a drive motor, 3 is a reducer, 4 is a support sleeve, 5 is a guard ring, 6 is a locking nut, 7 is a main frame, 8 is a core shaft moving frame, 9 is a bracket, 10 is a feed cylinder, 11 is a round blank, 12 is a slewing bearing, 13 is a guide plate, 14 is a cushion block, and 15 is a slide rail. DETAILED DESCRIPTION

[0038] The present invention is further described in detail below in conjunction with the accompanying drawings and embodiments.

[0039] like Figures 1 to 5 A vertical non-cutting insert rolling composite precision forming gear device is shown, which includes a main frame 7, a driving motor 2, a reducer 3 and two sets of precision forming devices, wherein: the upper end of the main frame 7 is set to an open shape, a guide plate 13 is covered at the open position of the upper end surface of the main frame 7, an axial hole is set in the middle of the guide plate 13, and long hole grooves are symmetrically set on both sides of the guide plate 13 along the diameter direction;

[0040] The drive motor 2 and the reducer 3 are both arranged in the main frame 7, the drive motor 2 is arranged in the horizontal direction, the rotor of the drive motor 2 is connected to the power input shaft of the reducer 3, the power output shaft of the reducer 3 is arranged vertically upward, the power output shaft of the reducer 3 is fixedly connected to the lower end of the support sleeve 4, the upper end of the support sleeve 4 passes through the shaft hole and extends to the outside of the main frame 7, the round blank 11 is clamped on the top of the support sleeve 4, and a rotary bearing 12 is arranged between the outer wall of the support sleeve 4 and the shaft hole; preferably, in order to ensure that the round blank 11 does not slip with the support sleeve 4 during the forming process, a magnetic suction cup or a vacuum suction cup is arranged on the upper end surface of the support sleeve 4, and the round blank 11 is magnetically sucked on the magnetic suction cup or adsorbed on the working surface of the vacuum suction cup;

[0041] The precision forming device comprises a guard ring 5, a locking nut 6, a precision forming gear roller 1, a mandrel moving frame 8, a bracket 9 and a feed cylinder 10. The guard ring 5 is fixedly sleeved on the outside of the guide plate 13, and the upper end surface of the guard ring 5 is higher than the upper surface of the guide plate 13. Two locking nuts 6 are arranged opposite to each other along the diameter direction of the guard ring 5. The locking nuts 6 penetrate the guard ring 5. A plurality of pads 14 are detachably arranged on the locking nuts 6 on the inner side of the guard ring 5.

[0042] The mandrel moving frame 8 is set in a C shape, and the two mandrel moving frames 8 are movably installed on the upper surface of the guide plate 13 respectively, and the two mandrel moving frames 8 are relatively arranged with respect to the axial direction of the round blank 11, and the edge of the round blank 11 is located in the groove of the opening of the mandrel moving frame 8, and the locking nut 6 drives the pad 14 to press the outer wall of the web of the mandrel moving frame 8; the bracket 9 is arranged above the mandrel moving frame 8, and the feed cylinder 10 is vertically installed on the bracket 9 downward, and the piston rod of the feed cylinder 10 is connected to the precision forming gear The upper end of the roller 1 is fixedly connected, and the lower end of the precision formed gear roller 1 passes through the bracket 9, the core shaft moving frame 8, the long hole groove from top to bottom in sequence and extends to the main frame 7. Forming teeth are arranged on the outer wall of the precision formed gear roller 1. The feed cylinder 10 drives the precision formed gear roller 1 to move downward along the axial direction. At the same time, the support sleeve 4 drives the precision formed gear roller 1 to rotate through the round blank 11. The precision formed gear roller 1 is continuously or intermittently fed downward in a spiral manner, and a composite gear tooth shape is formed on the outer cylindrical surface of the round blank 11 by inserting and rolling.

[0043] Furthermore, the fine forming gear roller 1 is configured as a plurality of long shaft parts with forming teeth, the plurality of forming teeth have an equal number of teeth and are connected in sequence, and the pitch circle Φ of each section of the fine forming gear roller 1 is 轴 The pitch circle of the gear after the round blank 11 is formed is Φ 坯 Tangent, and at any moment the pitch circle Φ 轴 With the pitch circle Φ 坯 The linear speed at the point of tangency is equal: v 轴 =v 坯 ; At any time, the dividing circle Φ 轴 With the pitch circle Φ 坯 The ratio of the angular velocities at the point of tangency is equal to the inverse ratio of the pitch circle diameter:

[0044] From the head to the tail of the fine forming gear roller 1, an initial guide section 1-1, a biting section 1-2, a material dividing section 1-3, a tooth profile preforming section 1-4, an involute forming section 1-5 and a tooth profile finishing section 1-6 are coaxially arranged in sequence according to the forming process;

[0045] The initial guide segment 1-1 is set to be cylindrical, and the length of the initial guide segment 1-1 is not less than 1 / 2 of the height of the blank; in the initial state of the insertion and rolling composite forming, the outer cylindrical surface of the initial guide segment 1-1 is tangent to the outer cylindrical surface of the round blank 11;

[0046] The biting section 1-2, the outer wall of the biting section 1-2 is set as a cone surface, the small end surface of the biting section 1-2 is connected to the initial guide section 1-1, and the outer wall of the biting section 1-2 is provided with biting cone teeth, and the taper of the biting cone teeth is α, 8°≤α≤15°;

[0047] The dividing section 1-3, the outer wall of the dividing section 1-3 is set as a conical surface, the small end surface of the dividing section 1-3 is connected to the large end surface of the biting section 1-2, and the outer wall of the dividing section 1-3 is provided with dividing cone teeth, each dividing cone tooth is respectively connected to the corresponding biting cone tooth, the taper of the dividing cone teeth is β, 3°≤β≤10°, and β<α, the ratio of the length of the generatrix of the biting section 1-2 to the length of the generatrix of the dividing section 1-3 is not greater than 1 / 3;

[0048] The tooth preforming section 1-4, the involute forming section 1-5 and the tooth finishing section 1-6 are all arranged as spur gear shafts, the tooth preforming section 1-4 is connected to the large end face of the dividing section 1-3, the number of teeth, module, addendum circle, root circle and base circle of the tooth preforming section 1-4, the involute forming section 1-5 and the tooth finishing section 1-6 are all the same, the tooth profile of the tooth preforming section 1-4 is a trapezoidal profile, and the tooth profile of the involute forming section 1-5 and the tooth finishing section 1-6 is an involute profile; wherein:

[0049] The tooth profile preforming section 1-4 is used to complete the preforming of the trapezoidal cross section of the entire forming tooth along the height direction of the round blank 11, that is, the volume of the forming tooth pressed into the gear by the tooth profile preforming section 1-4 of the precision forming gear roller 1 is equal to the volume of the blank being reversely squeezed into the tooth groove of the adjacent forming tooth;

[0050] The involute forming section 1-5 is used to form the gear tooth profile from a trapezoidal cross-sectional profile to an involute cross-sectional profile;

[0051] The tooth profile finishing section 1-6 finishes and shapes the tooth profile cross section into an involute gear.

[0052] Furthermore, in order to enable the precision formed gear roller 1 to be better introduced into the outer circle of the round blank 11, a positioning section 1-7 is provided at the front end of the initial guide section 1-1. The positioning section 1-7 is provided in a truncated cone shape, and the diameter of the large end of the positioning section 1-7 is equal to the diameter of the initial guide section 1-1.

[0053] Furthermore, slide rails 15 are respectively arranged on the upper surface of the guide plate 13 and at the front and rear sides of the cushion block 14 , and the cushion block 14 reciprocates along the slide rails.

[0054] The insertion and rolling composite forming process of the gear without cutting and cleaning is carried out by using the above-mentioned device, which comprises the following steps:

[0055] S1 initial guide: the round blank 11 is mounted on the support sleeve 4, and the locking nut 6 drives the pad 14 and the mandrel moving frame 8 to move toward the side of the round blank 11 along the long hole groove set on the guide plate 13, until the initial guide section 1-1 of the fine forming gear roller 1 presses the outer cylindrical surface of the round blank 11, and then a number of pads are inserted into the locking nut 6 according to the distance between the web of the mandrel moving frame 8 and the inner wall of the guard ring 5, and finally the locking nut 6 is locked;

[0056] S2, biting: the feed cylinder 10 and the drive motor 2 are started at the same time, the drive motor 2 drives the round blank 11 to rotate through the reducer 3 and the support sleeve 4, and the round blank 11 drives the fine forming gear roller 1 to rotate. At the same time, the feed cylinder 10 drives the fine forming gear roller 1 to move downward along the axial direction to the biting section 1-2, and the fine forming gear roller 1 is continuously or intermittently fed downward in a spiral along the axial direction, and a tooth groove corresponding to the biting bevel tooth shape is formed on the outer cylindrical surface of the round blank 11;

[0057] S3, material division: the feed cylinder 10 drives the fine forming gear roller 1 to continue to move downward along the axial direction to the material division section 1-3, the drive motor 2 keeps rotating at the speed in step S2, the fine forming gear roller 1 is continuously or intermittently fed downward along the axial direction, and a tooth groove corresponding to the tooth shape of the material division cone tooth is formed on the outer circumferential surface of the round blank 11;

[0058] S4, tooth profile preforming: the feed cylinder 10 drives the fine forming gear roller 1 to continue to move downward along the axial direction to the tooth profile preforming section 1-4, and the drive motor 2 keeps rotating at the speed in step S2, and the fine forming gear roller 1 is continuously or intermittently fed downward in a spiral along the axial direction to form tooth grooves corresponding to the tooth profiles of the tooth profile preforming sections 1-4 on the outer circumferential surface of the round blank 11;

[0059] S5, involute forming: the feed cylinder 10 drives the fine forming gear roller 1 to continue to move downward along the axial direction to the involute forming section 1-5, the drive motor 2 keeps rotating at the speed in step S2, the fine forming gear roller 1 is continuously or intermittently fed downward in a spiral along the axial direction, and the tooth groove formed on the outer cylindrical surface of the round blank 11 in step S4 is processed into an involute tooth groove;

[0060] S6, tooth shape finishing: the feed cylinder 10 drives the finely formed gear roller 1 to continue to move downward along the axis direction to the tooth shape finishing section 1-7, the drive motor 2 keeps rotating at the speed in step S2, the finely formed gear roller 1 is continuously or intermittently fed downward in a spiral along the axis direction, and the tooth shape finishing section 1-6 finishes the involute tooth groove formed on the outer cylindrical surface of the round blank 11 in step S5, completing the insertion and rolling composite non-cutting finely formed gear processing;

[0061] S7, the driving motor 2 stops working, and the feed cylinder 10 drives the precision-formed gear roller 1 to move upward along the axial direction until the precision-formed gear roller 1 is separated from the precision-formed gear, and then the non-cutting precision-formed gear is removed from the supporting sleeve 4, and the above steps S1 to S6 are repeated to perform the next round blank 11 insertion rolling composite non-cutting precision forming processing.

[0062] The above is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily thought of by a person skilled in the art within the technical scope disclosed by the present invention should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention shall be based on the protection scope of the claims.

Claims

1. A vertical non-cutting, inserting and rolling composite precision forming device for gears, comprising a main frame (7), a drive motor (2), a reducer (3) and two sets of precision forming devices, characterized in that: The upper end of the main frame (7) is arranged in an open shape, a guide plate (13) is arranged at the open position of the upper end surface of the main frame (7), an axial hole is arranged in the middle of the guide plate (13), and long hole grooves are symmetrically arranged on both sides of the guide plate (13) along the diameter direction; The drive motor (2) and the reducer (3) are both arranged in the main frame (7), the drive motor (2) is arranged in the horizontal direction, the rotor of the drive motor (2) is connected to the power input shaft of the reducer (3), the power output shaft of the reducer (3) is arranged vertically upward, the power output shaft of the reducer (3) is fixedly connected to the lower end of the support sleeve (4), the upper end of the support sleeve (4) passes through the shaft hole and extends to the outside of the main frame (7), the round blank (11) is clamped on the upper part of the support sleeve (4), and a slewing bearing (12) is arranged between the outer wall of the support sleeve (4) and the shaft hole; The precision forming device comprises a precision forming gear roller (1), a guard ring (5), a locking nut (6), a core shaft moving frame (8), a bracket (9) and a feed cylinder (10); the guard ring (5) is fixedly sleeved on the outside of a guide plate (13); the upper end surface of the guard ring (5) is higher than the upper surface of the guide plate (13); two locking nuts (6) are arranged opposite to each other along the diameter direction of the guard ring (5); the locking nuts (6) penetrate the guard ring (5); and a plurality of pads (14) are detachably arranged on the locking nut (6) on the inner side of the guard ring (5); The mandrel moving frame (8) is arranged in a C shape, and the two mandrel moving frames (8) are movably mounted on the upper surface of the guide plate (13), and the two mandrel moving frames (8) are arranged relative to each other with respect to the axial direction of the round blank (11), and the edge of the round blank (11) is located in the groove of the opening of the mandrel moving frame (8), and the locking nut (6) drives the pad (14) to press the outer wall of the web of the mandrel moving frame (8); the bracket (9) is arranged above the mandrel moving frame (8), and the feed oil cylinder (10) is vertically downwardly mounted on the bracket (9), and the piston rod of the feed oil cylinder (10) is in contact with the fine cleaning part. The upper end of the fine-shaped gear roller (1) is fixedly connected, and the lower end of the fine-shaped gear roller (1) passes through the bracket (9), the core shaft moving frame (8), the long hole groove from top to bottom in sequence and extends to the main frame (7). The outer wall of the fine-shaped gear roller (1) is provided with forming teeth. The feed cylinder (10) drives the fine-shaped gear roller (1) to move downward along the axial direction. At the same time, the support sleeve (4) drives the fine-shaped gear roller (1) to rotate through the round blank (11). The fine-shaped gear roller (1) is continuously or intermittently fed downward in a spiral manner to insert and grind the composite gear tooth shape on the outer cylindrical surface of the round blank (11).

2. The device for vertical non-cutting, inserting and rolling composite precision forming of gears according to claim 1 is characterized in that: The clean forming gear roller (1) is configured as a plurality of long shaft parts with forming teeth, the plurality of forming teeth have an equal number of teeth and are connected in sequence, and the pitch circle Φ of each section of the clean forming gear roller (1) is 轴 The pitch circle of the gear after the round blank (11) is formed is Φ 坯 Tangent, and at any moment the pitch circle Φ 轴 With the pitch circle Φ 坯 The linear speed at the point of tangency is equal: v 轴 =v 坯 ; At any time, the dividing circle Φ 轴 With the pitch circle Φ 坯 The ratio of the angular velocities at the point of tangency is equal to the inverse ratio of the pitch circle diameter: An initial guide section (1-1), a biting section (1-2), a material dividing section (1-3), a tooth profile preforming section (1-4), an involute forming section (1-5) and a tooth profile finishing section (1-6) are coaxially arranged in sequence from the head to the tail of the fine forming tooth roller (1) according to the forming process; An initial guide segment (1-1), the initial guide segment (1-1) is set to be cylindrical, and the length of the initial guide segment (1-1) is not less than 1 / 2 of the height of the blank; in the initial state of the insertion and rolling composite forming, the outer cylindrical surface of the initial guide segment (1-1) is tangent to the outer cylindrical surface of the round blank (11); A biting section (1-2), the outer wall of the biting section (1-2) is arranged as a conical surface, the small end surface of the biting section (1-2) is connected to the initial guide section (1-1), biting conical teeth are arranged on the outer wall of the biting section (1-2), the taper of the biting conical teeth is α, 8°≤α≤15°; A material dividing section (1-3), the outer wall of the material dividing section (1-3) is arranged as a conical surface, the small end surface of the material dividing section (1-3) is connected to the large end surface of the biting section (1-2), a material dividing cone tooth is arranged on the outer wall of the material dividing section (1-3), each material dividing cone tooth is respectively connected to the corresponding biting cone tooth, the taper of the material dividing cone tooth is β, 3°≤β≤10°, and β<α, and the ratio of the length of the generatrix of the biting section (1-2) to the length of the generatrix of the material dividing section (1-3) is not greater than 1 / 3; The tooth profile preforming section (1-4), the involute forming section (1-5) and the tooth profile finishing section (1-6) are all arranged as spur gear shafts, the tooth profile preforming section (1-4) is connected to the large end face of the dividing section (1-3), the tooth number, module, tooth top circle, tooth root circle and base circle of the tooth profile preforming section (1-4), the involute forming section (1-5) and the tooth profile finishing section (1-6) are all the same, the tooth profile profile of the tooth profile preforming section (1-4) is a trapezoidal profile, and the tooth profile profiles of the involute forming section (1-5) and the tooth profile finishing section (1-6) are involute profiles; wherein: The tooth profile preforming section (1-4) is used to complete the preforming of the trapezoidal cross section of the entire forming tooth along the height direction of the round blank (11), that is, the volume of the forming tooth pressed into the gear by the tooth profile preforming section (1-4) of the precision forming tooth roller (1) is equal to the volume of the blank extruded back into the tooth groove of the adjacent forming tooth; The involute forming section (1-5) is used to form the tooth profile of the gear from a trapezoidal cross-sectional profile to an involute cross-sectional profile; The tooth profile finishing section (1-6) finishes and shapes the tooth profile section into an involute gear.

3. The device for vertical non-cutting, inserting and rolling composite precision forming of gears according to claim 1 is characterized in that: A positioning section (1-7) is arranged at the front end of the initial guide section (1-1); the positioning section (1-7) is arranged in a truncated cone shape; and the diameter of the large end of the positioning section (1-7) is equal to the diameter of the initial guide section (1-1).

4. The device for vertical non-cutting, inserting and rolling composite precision forming of gears according to claim 1 is characterized in that: Slide rails (15) are respectively arranged on the upper surface of the guide plate (13) and at the front and rear sides of the cushion block (14), and the cushion block (14) moves back and forth along the slide rails.

5. The device for vertical non-cutting, inserting and rolling composite precision forming of gears according to claim 1 is characterized in that: A magnetic suction cup or a vacuum suction cup is arranged on the upper end surface of the support sleeve (4), and the round blank (11) is magnetically sucked on the magnetic suction cup or adsorbed on the working surface of the vacuum suction cup.

6. The device as claimed in claim 1 is used to carry out a composite forming process of insert rolling for non-cutting clean-forming gears, characterized in that: The following steps are involved: S1, initial guide: the round blank (11) is mounted on the support sleeve (4), and the locking nut (6) drives the pad (14) and the mandrel moving frame (8) to move along the long hole groove provided on the guide plate (13) toward one side of the round blank (11) until the initial guide section (1-1) of the fine forming gear roller (1) presses the outer cylindrical surface of the round blank (11), and then a plurality of pads are inserted into the locking nut (6) according to the distance between the web of the mandrel moving frame (8) and the inner wall of the guard ring (5), and finally the locking nut (6) is locked; S2, biting: the feed cylinder (10) and the drive motor (2) are started simultaneously, the drive motor (2) drives the round blank (11) to rotate through the reducer (3) and the support sleeve (4), the round blank (11) drives the fine forming gear roller (1) to rotate, at the same time, the feed cylinder (10) drives the fine forming gear roller (1) to move downward along the axial direction to the biting section (1-2), the fine forming gear roller (1) is continuously or intermittently fed downward in a spiral along the axial direction, and a tooth groove corresponding to the biting bevel tooth shape is formed on the outer circumferential surface of the round blank (11); S3, material division: the feed cylinder (10) drives the fine forming gear roller (1) to continue to move downward along the axial direction to the material division section (1-3), the drive motor (2) keeps rotating at the speed in step S2, the fine forming gear roller (1) is continuously or intermittently fed downward in a spiral along the axial direction, and tooth grooves corresponding to the tooth shape of the material division cone teeth are formed on the outer circumferential surface of the round blank (11); S4, tooth profile preforming: the feed cylinder (10) drives the fine forming tooth roller (1) to continue to move downward along the axial direction to the tooth profile preforming section (1-4), the drive motor (2) keeps rotating at the speed in step S2, the fine forming tooth roller (1) is continuously or intermittently fed downward in a spiral along the axial direction, and a tooth groove corresponding to the tooth profile of the tooth profile preforming section (1-4) is formed on the outer circumferential surface of the round blank (11); S5, involute forming: the feed cylinder (10) drives the fine forming gear roller (1) to continue to move downward along the axial direction to the involute forming section (1-5), the drive motor (2) keeps rotating at the speed in step S2, the fine forming gear roller (1) is continuously or intermittently fed downward in a spiral along the axial direction, and the tooth groove formed on the outer circumferential surface of the round blank (11) in step S4 is processed into an involute tooth groove; S6, tooth shape finishing: the feed cylinder (10) drives the finely formed gear roller (1) to continue to move downward along the axis direction to the tooth shape finishing section (1-7), the drive motor (2) keeps rotating at the speed in step S2, the finely formed gear roller (1) is continuously or intermittently fed spirally downward along the axis direction, and the tooth shape finishing section (1-6) finishes the involute tooth groove formed on the outer cylindrical surface of the round blank (11) in step S5, thereby completing the insertion and rolling composite non-cutting finely formed gear processing; S7, the driving motor (2) stops working, and the feed cylinder (10) drives the precision-formed gear roller (1) to move upward along the axial direction until the precision-formed gear roller (1) is separated from the precision-formed gear, and then the non-cut precision-formed gear is removed from the support sleeve (4), and the above steps S1 to S6 are repeated to carry out the next round blank (11) insertion rolling composite non-cut precision forming process.

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