Harmonic reducer flexible gear pre-forming machining transfer die

Abstract

The utility model discloses a harmonic reducer flexible gear pre-forming machining transfer die which comprises a first die body, a second die body, a third die body, a fourth die body, a fifth die body, a sixth die body, a seventh die body and an eighth die body which are used for machining material pieces in sequence. The second die assembly and the third die assembly are used for shaping the outline of the boss, the fourth die assembly is used for punching a center hole in the boss, the fifth die assembly is used for stretching the boss with the center hole into a cylinder, the sixth die assembly is used for compressing the R angle of the connecting position of the cylinder and a flange, and the seventh die assembly is used for punching a flange hole in a material sheet. And the eighth die is closed to punch the flange on the material sheet so as to realize blanking, and the flange hole is formed in the flange. According to the scheme, material deformation is effectively controlled, stress concentration is reduced, and geometric accuracy and structural stability of the cylinder and the flange are ensured through the progressive machining process of seven sets of dies and the synergistic effect of staged and multi-procedure.

Description

Technical Field

[0001] This application relates to the field of mold technology for manufacturing flexible wheels of harmonic reducers, and in particular to a transfer mold for the initial forming of flexible wheels of harmonic reducers. Background Technology

[0002] A harmonic reducer is a precision speed reduction device that utilizes the elastic deformation of flexible elements to transmit motion and power. It consists of a wave generator, a flexible wheel, and a rigid wheel. The wave generator, fitted with a flexible bearing, causes the flexible wheel to undergo controllable elastic deformation, meshing with the rigid wheel to transmit motion and power—a gear transmission mechanism. The core of the harmonic reducer lies in the elastic deformation of the flexible wheel, achieving high reduction ratios, high precision, and high rigidity. The cap-shaped flexible wheel is a common type of flexible wheel. Its forming process requires pre-machining a flexible wheel blank, including a thin-walled cylinder and a flange. Then, tooth profiles are machined on the thin-walled cylinder. Finally, the entire flexible wheel is formed through a series of steps including heat treatment and precision machining. Traditional flexible wheel blank machining methods often suffer from cumbersome processing steps and difficulty in guaranteeing forming accuracy, resulting in low production efficiency and inconsistent product quality. Utility Model Content

[0003] This application provides a transmission mold for the initial forming of the flexural wheel of a harmonic reducer, in order to improve or solve at least one of the above-mentioned technical problems.

[0004] The technical solution adopted in this application is as follows:

[0005] A transfer mold for initial forming of a flex wheel in a harmonic reducer is provided for processing a sheet material into a flex wheel blank. The flex wheel blank includes a cylinder and a flange, with one end of the cylinder connected to the flange. The transfer mold includes a first mold, a second mold, a third mold, a fourth mold, a fifth mold, a sixth mold, a seventh mold, and an eighth mold that process the sheet material sequentially. The first mold pre-stretches the sheet material to form a boss when closed. The second mold and the third mold both shape the outline of the boss when closed. The fourth mold punches a center hole on the boss when closed. The fifth mold stretches the boss with the center hole into a cylinder when closed. The sixth mold compresses the radius (R) at the connection point between the cylinder and the flange when closed. The seventh mold punches a flange hole on the sheet material when closed. The eighth mold cuts out a flange from the sheet material to achieve blanking. The flange hole is located on the flange.

[0006] In the technical solution, through the progressive processing flow (pre-stretching, twice contour shaping, center hole punching, cylinder body stretching, R angle shaping, flange hole punching, and edge cutting) of eight sets of molds, the complete process integration from the material sheet to the forming of the flexible gear blank is realized. The first mold pre-stretches to form a boss, the second and third molds gradually optimize the boss contour, the fourth mold accurately punches the center hole, the fifth mold forms the cylinder body by stretching, the sixth mold compresses the R angle, the seventh mold punches the flange hole, and the eighth mold completes the flange blanking. Through the synergistic effect of the multiple stages and multiple processes, each mold only undertakes a single deformation task (such as pre-stretching of the first mold and stretching of the cylinder body by the fifth mold), avoiding the risk of material fatigue or fracture caused by the superposition of complex processes. Through the gradual shaping of the second and third molds, the boss contour accuracy is ensured, providing a reference for subsequent cylinder body stretching, effectively controlling material deformation, reducing stress concentration, ensuring the geometric accuracy and structural stability of the cylinder body and flange, and improving processing efficiency. After the cylinder body is stretched by the fifth mold, the sixth mold is specially designed to compress the R angle at the junction of the cylinder body and the flange, eliminating the round angle rebound after stretching, reducing the stress concentration in this area, and improving the fatigue life of the flexible gear.

[0007] The first mold includes a first mold seat provided with a pre-stretching concave die and a pre-stretching convex die located below the pre-stretching concave die. When the pre-stretching concave die and the pre-stretching convex die are closed, the surface profile of the pre-stretching convex die forms a boss in the pre-stretching concave die. The boss includes a flat area in the middle and an arc surface area around the flat area. The cross-section of the arc surface area is S-shaped, and the upper and lower ends of the arc surface area are connected by a round corner.

[0008] In the technical solution, the pre-stretching concave die and the convex die of the first mold form a boss structure with an S-shaped arc surface area. The round corner transition design of the flat area and the arc surface area optimizes material flow, avoids local excessive thinning or cracking during stretching, and provides a uniform initial form for subsequent shaping processes.

[0009] The second mold includes a second mold seat provided with a first shaping concave die and a first shaping convex die located below the first shaping concave die. When the first shaping concave die and the first shaping convex die are closed, the round corners at the upper and lower ends of the arc surface area are reduced. The third mold includes a third mold seat provided with a second shaping concave die and a second shaping convex die located below the second shaping concave die. When the second shaping concave die and the second shaping convex die are closed, the diameter of the flat area is increased.

[0010] In the technical solution, the second mold reduces the round corners of the arc surface area, and the third mold increases the diameter of the flat area. The step-by-step shaping technology can gradually correct the detail errors of the boss contour, reduce the deformation amount of single processing, improve the size consistency, and ensure the positioning accuracy of subsequent center hole punching and cylinder body stretching.

[0011] The first die holder is provided with a first ejector for separating the material sheet from the pre-stretching die; the second die holder is provided with a second ejector for separating the material sheet from the first shaping die; and the third die holder is provided with a third ejector for separating the material sheet from the second shaping die.

[0012] In the technical solution, the setting of the die ejectors can quickly separate the material sheet from the die, avoid die sticking or surface scratching, ensure processing continuity, reduce manual intervention, and improve the degree of automation.

[0013] The fourth die includes a fourth die holder provided with a first clamping block and a second clamping block located below the first clamping block, the first clamping block and the second clamping block can clamp and position the boss, the first clamping block is provided with a center punch, the second clamping block is provided with a blanking hole corresponding to the center punch, and the center punch can move to the blanking hole to punch a center hole on the boss.

[0014] In the technical solution, the fourth die adopts the first clamping block and the second clamping block to double-position the boss, and combines the precise positioning of the center punch and the blanking hole to ensure the coaxiality and hole size precision of the center hole, providing a reliable reference for the stretching of the cylinder.

[0015] The fifth die includes a fifth die holder provided with a third clamping block and a fourth clamping block located below the third clamping block, the third clamping block and the fourth clamping block can clamp and position the area around the boss, and the fifth die holder is also provided with a stretching punch, the stretching punch can move up and pass through the center hole to stretch the boss with the center hole into a cylinder.

[0016] In the technical solution, the fifth die fixes the area around the boss through the third clamping block and the fourth clamping block, and the stretching punch uses the center hole as a guide reference to stretch the boss into a cylinder, and the synergistic effect of clamping force and stretching force can prevent uneven wall thickness or sidewall wrinkles of the cylinder.

[0017] The sixth die includes a sixth die holder provided with a supporting block, a third shaping die, and a shaping pressing block, the supporting block is used to support the material sheet, the inner contour of the third shaping die is matched with the outer contour of the cylinder, and the shaping pressing block is arranged in the third shaping die in a lifting manner; the third shaping die presses the area around the cylinder downward, and the shaping pressing block presses the cylinder downward to compress and shape the R angle of the flange connection position of the cylinder.

[0018] In the technical solution, the fifth die and the sixth die step by step compress and reshape the R angle of the flange connection position of the cylinder, so that the R angle is gradually reduced, the deformation amount of single processing is reduced, the error and the risk of R angle breakage are reduced, and the processing precision is ensured. After the R angle is compressed, the material compression rate is improved, and the risk of micro-cracks at the fillet is eliminated.

[0019] The sixth die seat is provided with a hydraulic ejector rod and an inner diameter protection punch matched with the inner contour of the cylinder, the hydraulic ejector rod drives the reshaping block to move up and down, and the inner diameter protection punch extends into the cylinder when the third reshaping concave die and the reshaping block compress and reshape the R angle, so as to support the wall of the cylinder.

[0020] In the technical solution, when the third reshaping concave die and the reshaping block compress and reshape the R angle, the inner diameter protection punch supports the cylinder radially in the cylinder to prevent radial deformation of the cylinder.

[0021] The seventh die includes a seventh die seat, the seventh die seat is provided with a flange hole punch, a fifth clamping block and a sixth clamping block located below the fifth clamping block, the fifth clamping block and the sixth clamping block can clamp and position the area around the cylinder, and the flange hole punch moves to punch the flange hole around the cylinder.

[0022] In the technical solution, when the seventh die punches the flange hole around the cylinder, the fifth clamping block and the sixth clamping block fix the area around the cylinder, avoid the hole position deviation or hole diameter deformation caused by material displacement during punching process, and ensure the uniformity of flange hole distribution.

[0023] The seventh die also includes a first inner lining block, which can support the wall of the cylinder in the cylinder.

[0024] In the technical solution, the first inner lining block provides radial support inside the cylinder, offsets the extrusion force of the material to the outside during punching, prevents the cylinder wall from collapsing or the flange hole edge from warping, and improves the perpendicularity of the hole wall.

[0025] The eighth die includes an eighth die seat, the eighth die seat is provided with a trimming punch, a seventh clamping block and an eighth clamping block located below the seventh clamping block, the seventh clamping block and the eighth clamping block can clamp and position the area around the cylinder, and the trimming punch moves to punch the flange around the cylinder.

[0026] In the technical solution, the eighth die accurately punches the outer contour of the flange through the cooperation of the trimming punch, the seventh clamping block and the eighth clamping block, the seventh clamping block and the eighth clamping block fix the area around the cylinder to avoid burrs or deformation caused by trimming vibration, and ensure the perpendicularity and connection strength of the flange and the cylinder.

[0027] The eighth die further comprises a second inner pad capable of forming support to the wall of the barrel within the barrel.

[0028] In the technical solution, the second inner pad forms full circumferential support to the inner wall of the barrel when the flange is punched, balances the radial shearing force of the trimming punch, and prevents the out-of-tolerance of the barrel ovality or the tearing defect at the cutout.

[0029] Thanks to the above technical solution, the technical effects achieved by the present application are as follows: through the progressive processing flow of the eight sets of dies (pre-stretching, twice profile shaping, punching the center hole, stretching the barrel, R angle shaping, punching the flange hole, and trimming), the complete process integration from the material sheet to the forming of the flexible gear blank is realized. The first die pre-stretches to form the boss, the second and third dies gradually optimize the boss profile, the fourth die accurately punches the center hole, the fifth die forms the barrel through stretching, the sixth die compresses the R angle, the seventh die punches the flange hole, and the eighth die completes the flange trimming. Through the synergistic effect of the stages and multiple processes, each die only undertakes a single deformation task (such as the first die pre-stretching and the fifth die stretching the barrel), the risk of material fatigue or fracture caused by the superposition of complex processes is avoided, the boss profile accuracy is ensured through the gradual shaping of the second and third dies, the reference for the subsequent barrel stretching is provided, the material deformation is effectively controlled, the stress concentration is reduced, the geometric accuracy and structural stability of the barrel and the flange are ensured, and the processing efficiency is improved. After the barrel is stretched by the fifth die, the sixth die specially compresses the R angle at the connection between the barrel and the flange, eliminates the round angle rebound after stretching, reduces the stress concentration in this area, and improves the fatigue life of the flexible gear. BRIEF DESCRIPTION OF DRAWINGS

[0030] The accompanying drawings, which are included to provide a further understanding of the present application, constitute a part of the present application and illustrate the illustrative embodiments of the present application and its description serve to explain the present application, but do not constitute improper limitations on the present application. In the drawings:

[0031] Figure 1 The material sheet processing deformation process provided by the embodiments of the present application includes, from top to bottom, the state before processing, the state after processing by the first die (the dashed line is the state before shaping), the state after processing by the second die (the dashed line is the state before shaping), the state after processing by the third die, the state after processing by the fourth die, the state after processing by the fifth die, the state after processing by the sixth die, the state after processing by the seventh die, and the state after processing by the eighth die;

[0032] Figure 2 The structure schematic diagram of the first die processing the material sheet provided by the embodiments of the present application;

[0033] Figure 3A structure schematic view of a second die machining material piece provided by the embodiment of the present application;

[0034] Figure 4 A structure schematic view of a third die machining material piece provided by the embodiment of the present application;

[0035] Figure 5 A structure schematic view of a fourth die machining material piece provided by the embodiment of the present application;

[0036] Figure 6 A structure schematic view of a fifth die machining material piece provided by the embodiment of the present application;

[0037] Figure 7 A structure schematic view of a sixth die machining material piece provided by the embodiment of the present application;

[0038] Figure 8 A structure schematic view of a seventh die machining material piece provided by the embodiment of the present application;

[0039] Figure 9 A structure schematic view of an eighth die machining material piece provided by the embodiment of the present application.

[0040] Parts and list of reference numerals:

[0041] 1 material piece, 11 boss, 111 planar area, 112 arc surface area, 12 center hole;

[0042] 2 flexspline blank, 21 barrel, 22 flange, 23 flange hole;

[0043] 3 first die, 31 first die seat, 32 pre-stretching concave die, 33 pre-stretching convex die, 34 first ejector;

[0044] 4 second die, 41 second die seat, 42 first shaping concave die, 43 first shaping convex die, 44 second ejector;

[0045] 5 third die, 51 third die seat, 52 second shaping concave die, 53 second shaping convex die, 54 third ejector;

[0046] 6 fourth die, 61 fourth die seat, 62 first clamping block, 63 second clamping block, 64 center punch, 65 blanking hole;

[0047] 7 fifth die, 71 fifth die seat, 72 third clamping block, 73 fourth clamping block, 74 stretching punch;

[0048] 8 seventh die, 81 seventh die seat, 82 flange hole punch, 83 fifth clamping block, 84 sixth clamping block, 85 first inner lining block;

[0049] 9 eighth die, 91 eighth die holder, 92 trimming punch, 93 seventh clamping block, 94 eighth clamping block, 95 second inner lining block;

[0050] 100 sixth die, 101 sixth die holder, 102 supporting block, 103 third sizing recess, 104 sizing pressing block, 105 hydraulic ejector rod, 106 inner diameter protection punch. DETAILED DESCRIPTION

[0051] In order to more clearly illustrate the overall concept of the present application, the following will be described in detail with reference to the accompanying drawings.

[0052] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present application. However, it will be apparent to one skilled in the art that the present application can be practiced without the specific details and other implementations can be employed. Therefore, the scope of the present application is defined by the appended claims, not by the specific embodiments that are described herein.

[0053] In addition, in the description of the present application, it should be understood that the terms "upper", "lower", "top", "bottom", "inner", "outer", "axial", "radial", "circumferential", "transverse", "longitudinal", and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are merely for the purpose of facilitating the description of the present application and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application.

[0054] In the present application, unless specifically defined and limited otherwise, the terms "mount", "connect", "connection", "fixed", and the like should be interpreted broadly, for example, can be fixed connection, can also be detachable connection, or integral; can be mechanical connection, can also be electrical connection, or communication; can be directly connected, or indirectly connected through an intermediate medium; can be the internal communication of two elements or the interaction relationship between two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0055] In the present application, unless specifically defined and limited otherwise, the first feature is "on" or "under" the second feature, which can be direct contact between the first and second features, or indirect contact between the first and second features through an intermediate medium. In the description of the specification, the description of the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" means that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. In the present specification, the illustrative description of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0056] The application provides a transmission die for initial forming of a flexible gear of a harmonic reducer. The following description is based on the structure of the product and is provided for the purpose of illustration and understanding. It should be understood by those skilled in the art that the above structure is only a specific example and a schematic description, and cannot be regarded as a specific limitation of the technical solutions provided by the application.

[0057] Reference Figures 1 to 9 As shown in the drawings, the embodiment relates to a transmission die for initial forming of a flexible gear of a harmonic reducer, which is used for processing a blank 1 into a flexible gear blank 2. The flexible gear blank 2 comprises a barrel 21 and a flange 22, and the barrel 21 is connected to the flange 22 at one end of the barrel. Overall, the transmission die comprises a first die 3, a second die 4, a third die 5, a fourth die 6, a fifth die 7, a sixth die 100, a seventh die 8 and an eighth die 9, which are sequentially used for processing the blank 1. The first die 3 is used for pre-stretching the blank 1 to form a boss 11. The second die 4 and the third die 5 are used for shaping the profile of the boss 11. The fourth die 6 is used for punching a center hole 12 on the boss 11. The fifth die 7 is used for stretching the boss 11 with the center hole 12 into the barrel 21. The sixth die 100 is used for compressing the R angle at the connection position between the barrel and the flange. The seventh die 8 is used for punching a flange hole 23 on the blank 1. The eighth die 9 is used for blanking the flange 22 on the blank 1. The flange hole 23 is located on the flange 22.

[0058] Preferably, as Figures 2 to 8As shown, the first die 3 comprises a first die seat 31, which is provided with a first top piece 34, a pre-stretching female die 32 and a pre-stretching male die 33 below the pre-stretching female die 32; the second die 4 comprises a second die seat 41, which is provided with a second top piece 44, a first shaping female die 42 and a first shaping male die 43 below the first shaping female die 42; the third die 5 comprises a third die seat 51, which is provided with a third top piece 54, a second shaping female die 52 and a second shaping male die 53 below the second shaping female die 52; the first top piece 34 is used for separating the material sheet 1 and the pre-stretching female die 32; the fourth die 6 comprises a fourth die seat 61, which is provided with a first clamping block 62 and a second clamping block 63 below the first clamping block 62, the first clamping block 62 is provided with a center punch 64, and the second clamping block 63 is provided with a blanking hole 65 corresponding to the center punch 64; the fifth die 7 comprises a fifth die seat 71, which is provided with a stretching punch 74, a third clamping block 72 and a fourth clamping block 73 below the third clamping block 72; the sixth die 100 comprises a sixth die seat 101, which is provided with a supporting block 102, a third shaping female die 103, a shaping pressing block 104, a hydraulic top rod 105 and an inner diameter protection punch 106; the seventh die 8 comprises a seventh die seat 81, which is provided with a flange hole punch 82, a first inner lining block 85, a fifth clamping block 83 and a sixth clamping block 84 below the fifth clamping block 83; the eighth die 9 comprises an eighth die seat 91, which is provided with a trimming punch 92, a second inner lining block 95, a seventh clamping block 93 and an eighth clamping block 94 below the seventh clamping block 93.

[0059] Based on the above overall introduction, as Figure 1 As shown, the structure of the material sheet 1 in each die in the transfer die processing process is changed, and finally the formed flexible gear blank 2 is discharged. Specifically, the power required for stamping, stretching, blanking, shaping, compression, inner lining and other actions in the transfer die can be provided by a hydraulic mechanism.

[0060] The transfer die is composed of the first to eighth dies arranged in sequence, and the functions of each die are as follows:

[0061] The first die 3 processes:

[0062] As Figure 2As shown, firstly, the sheet material 1 is placed between the pre-stretching die 32 and the pre-stretching punch 33 of the first mold 3, and the mold closing action is initiated. At this time, the pre-stretching punch 33 on the first mold base 31 moves upward and engages with the pre-stretching die 32. The surface contour of the pre-stretching punch 33 and the pre-stretching die 32 work together to apply pressure to the sheet material 1, causing the sheet material 1 to gradually form a boss 11 within the pre-stretching die 32. The boss 11 has a flat area 111 in the middle, and the arc area 112 surrounding the flat area 111 has an S-shaped cross-section, with the upper and lower ends of the arc area 112 transitioning through rounded corners. The formation of the boss 11 through such pre-stretching is the basis for subsequent processing. This special-shaped boss 11 allows the material to flow and deform better according to design requirements during subsequent shaping operations, ensuring the smooth progress of the entire flexible wheel blank 2 processing process and improving the structural stability of the final flexible wheel. When the mold is closed and the boss 11 is formed, the pre-stretch die 32 and the pre-stretch punch 33 separate. The first ejector 34 set on the first mold base 31 plays a role in separating the sheet 1 from the pre-stretch die 32 so that the sheet 1 can smoothly enter the next mold processing step.

[0063] Second mold 4 processing:

[0064] like Figure 3 As shown, the sheet material 1 with the boss 11, taken from the first mold 3, is placed into the first forming die 42 and the first forming punch 43 of the second mold 4. The mold closing action is initiated, and the first forming punch 43 on the second mold base 41 moves upward to engage with the first forming die 42. During the mold closing process, the first forming die 42 and the first forming punch 43 shape the rounded corners at both ends of the arc area 112 of the boss 11, reducing their rounded corners and making the contour of the boss 11 more precise, better meeting the requirements of subsequent processing and the final design of the flexible gear. This shaping improves the accuracy of subsequent processing dimensions, helps improve the transmission accuracy of the harmonic reducer, and ensures its stable operation. After shaping, when the first forming die 42 and the first forming punch 43 separate, the second ejector 44 on the second mold base 41 operates, separating the sheet material 1 from the first forming die 42, allowing the sheet material 1 to continue flowing to the third mold 5 for the next step of processing.

[0065] Third mold 5 processing:

[0066] like Figure 4As shown, the sheet material 1, processed by the second mold 4, is placed between the second shaping die 52 and the second shaping punch 53 of the third mold 5. The mold closing action is initiated, and the second shaping punch 53 moves upward to engage with the second shaping die 52. During mold closing, the second shaping die 52 and the second shaping punch 53 act on the planar area 111 of the boss 11, increasing the diameter of the planar area 111. This further refines the contour of the boss 11, improving the overall accuracy of the subsequently processed flexible wheel and playing a crucial role in enhancing the performance of the harmonic reducer. After processing, when the second shaping die 52 and the second shaping punch 53 separate, the third ejector 54 on the third mold base 51 separates the sheet material 1 from the second shaping die 52, preparing to send the sheet material 1 to the fourth mold 6.

[0067] Fourth mold 6 processing:

[0068] like Figure 5 As shown, the sheet material 1 is placed into the fourth mold 6. The first clamping block 62 and the second clamping block 63 of the fourth mold 6 cooperate to clamp and position the boss 11, ensuring that the boss 11 is stable in position during the subsequent punching of the center hole 12. Next, the center punch 64 inside the first clamping block 62 moves downward toward the unloading hole 65 of the second clamping block 63, and punches the center hole 12 on the boss 11 using punching pressure. The punching of the center hole 12 provides an accurate positioning reference for the subsequent stretching of the boss 11 into the cylinder 21, ensuring the coaxiality of the cylinder 21 during stretching, avoiding problems such as eccentricity that affect the quality of the flexspline, thereby improving the quality of the flexspline and ensuring that it can play a good role in the harmonic reducer.

[0069] Fifth mold 7 processing:

[0070] like Figure 6 As shown, the sheet 1 with the center hole 12 is placed in the fifth mold 7. The third clamping block 72 and the fourth clamping block 73 of the fifth mold 7 work together to clamp and position the area around the boss 11, ensuring the stability of the sheet 1 during processing. Then, the stretching punch 74 on the fifth mold base 71 moves upward and passes through the previously punched center hole 12. The stretching punch 74 applies tension to the sheet 1, gradually stretching the boss 11 with the center hole 12 into a cylinder 21. In this process, due to the reasonable clamping and positioning and the design of the stretching punch 74, the cylinder 21 can be uniformly formed with good wall thickness uniformity, ensuring the mechanical properties of the flex wheel cylinder 21, enabling it to better withstand various forces during the operation of the harmonic reducer, and improving the service life and reliability of the flex wheel.

[0071] Machining of the sixth mold (100):

[0072] like Figure 7As shown, the blank 1 of the punched cylinder 21 is placed in the sixth mold 100. The support block 102 supports the blank. The third forming die 103 works in conjunction with the support block 102. The inner diameter protection punch 106 moves upward and enters the cylinder to support the wall of the cylinder. The third forming die 103 moves downward and presses the area around the cylinder, so that the lower half of the R-angle is compressed and flattened. At the same time, the hydraulic push rod 105 drives the forming pressure block 104 to press the cylinder downward, so that the upper half of the R-angle is compressed. With the cooperation of the third forming die 103 and the forming pressure block 104, the R-angle shrinks and the material accumulates in the forming pressure block 104, eliminating the risk of micro-cracks at the rounded corner.

[0073] Seventh mold 8 processing:

[0074] like Figure 8 As shown, the sheet 1, stretched into a cylindrical body 21, is placed into the seventh mold 8. The fifth clamping block 83 and the sixth clamping block 84 of the seventh mold 8 clamp and position the area around the cylindrical body 21. At the same time, the first inner liner block 85 provides support to the wall of the cylindrical body 21 inside the cylindrical body 21, preventing the cylindrical body 21 from deforming due to force during the punching of the flange holes 23. Subsequently, the flange hole punch 82 moves to punch the flange holes 23 around the cylindrical body 21, ensuring the positional accuracy of the flange holes 23 and the shape accuracy of the cylindrical body 21. This allows the flexible wheel to accurately cooperate with other components during subsequent assembly, ensuring the overall assembly accuracy and performance of the harmonic reducer.

[0075] Eighth mold 9 processing:

[0076] like Figure 9 As shown, the sheet material 1 is placed into the eighth mold 9. The seventh clamping block 93 and the eighth clamping block 94 of the eighth mold 9 clamp and position the area around the cylinder 21, and the second inner liner block 95 supports the wall of the cylinder 21 inside the cylinder 21, maintaining the shape of the cylinder 21. Then, the cutting punch 92 moves to punch out the flange 22 around the cylinder 21, realizing the blanking operation, and finally obtaining the flex wheel blank 2 that meets the requirements. Through this processing method, the blanking accuracy is guaranteed, while maintaining the integrity of the cylinder 21, so that the produced flex wheel blank 2 can meet the high performance requirements of the harmonic reducer, providing a reliable basic component for the production of high-quality harmonic reducers.

[0077] In the technical solution, through the progressive processing flow of the eight sets of molds (pre-stretching → twice contour shaping → punching the center hole 12 → stretching the barrel body 21 → R angle shaping → punching the flange hole 23 → cutting edge blanking), the complete process integration from the material sheet 1 to the forming of the flexible gear blank 2 is realized. The first mold 3 pre-stretches to form the boss 11, the second mold 4 and the third mold 5 gradually optimize the boss 11 contour, the fourth mold 6 precisely punches the center hole 12, the fifth mold 7 forms the barrel body 21 by stretching, the sixth mold 100 compresses the R angle, the seventh mold 8 punches the flange hole 23, and the eighth mold 9 completes the flange 22 blanking. Through the synergistic effect of the stages and multiple processes, each mold only undertakes a single deformation task (such as the first mold 3 pre-stretching and the fifth mold 7 stretching the barrel body 21), avoiding the risk of material fatigue or fracture caused by complex process superposition. Through the gradual shaping of the second mold 4 and the third mold 5, the contour accuracy of the boss 11 is ensured, providing a reference for subsequent barrel body 21 stretching, effectively controlling material deformation, reducing stress concentration, and ensuring the geometric accuracy and structural stability of the barrel body 21 and the flange 22, while improving processing efficiency. After the fifth mold 7 stretches the barrel body 21, the sixth mold 100 specially compresses the R angle at the connection between the barrel body 21 and the flange, eliminating the round corner rebound after stretching, reducing stress concentration in this area, and improving the fatigue life of the flexible gear.

[0078] The places not mentioned in the application can be realized by using or referring to the existing technology.

[0079] Each embodiment in the specification is described in a progressive manner, and the same or similar parts between each embodiment can be referred to each other. Each embodiment focuses on the differences from other embodiments.

[0080] The above only describes the embodiments of the application and is not intended to limit the application. The application can have various changes and modifications for those skilled in the art. Any modification, equivalent replacement, improvement, etc. within the spirit and principles of the application shall be included in the scope of the claims of the application.

Claims

1. A transfer die for machining a strip into a flexible gear wheel blank, the flexible gear wheel blank comprising a web and a flange, the web being connected to the flange at one end of the web, the transfer die being characterized in that, The transfer die comprises a first die, a second die, a third die, a fourth die, a fifth die, a sixth die, a seventh die and an eighth die which process the material sheet in sequence, the first die pre-stretches the material sheet to form a boss, the second die and the third die shape the profile of the boss, the fourth die punches a center hole on the boss, the fifth die stretches the boss with the center hole into a cylinder, the sixth die compresses the R angle of the position where the cylinder is connected with the flange, the seventh die punches a flange hole on the material sheet, and the eighth die punches a flange on the material sheet to realize blanking, and the flange hole is located on the flange.

2. The harmonic reducer flexspline initial forming machining transfer mold according to claim 1, characterized in that, The first die comprises a first die seat, the first die seat is provided with a pre-stretching female die and a pre-stretching male die below the pre-stretching female die, when the pre-stretching female die and the pre-stretching male die are closed, the surface profile of the pre-stretching male die forms a boss in the pre-stretching female die, the boss comprises a planar area in the middle and an arc surface area around the planar area, the cross section of the arc surface area is S-shaped, and the upper and lower ends of the arc surface area are respectively connected by a round corner.

3. The harmonic reducer flexspline initial forming machining transfer mold according to claim 2, characterized in that, The second die comprises a second die seat, the second die seat is provided with a first shaping female die and a first shaping male die below the first shaping female die, when the first shaping female die and the first shaping male die are closed, the round corners of the upper and lower ends of the arc surface area are reduced; The third die comprises a third die seat, the third die seat is provided with a second shaping female die and a second shaping male die below the second shaping female die, when the second shaping female die and the second shaping male die are closed, the diameter of the planar area is increased.

4. The harmonic reducer flexspline initial forming machining transfer mold according to claim 3, characterized in that, The first die seat is provided with a first ejector, the first ejector is used to separate the material sheet and the pre-stretching female die; the second die seat is provided with a second ejector, the second ejector is used to separate the material sheet and the first shaping female die, and the third die seat is provided with a third ejector, the third ejector is used to separate the material sheet and the second shaping female die.

5. The harmonic reducer flexspline initial forming machining transfer mold of claim 1, wherein, The fourth die comprises a fourth die seat, the fourth die seat is provided with a first clamping block and a second clamping block below the first clamping block, the first clamping block and the second clamping block can clamp and position the boss, the first clamping block is provided with a center punch, the second clamping block is provided with a blanking hole corresponding to the center punch, and the center punch can move to the blanking hole to punch a center hole on the boss.

6. The harmonic reducer flexspline initial forming machining transfer mold of claim 1, wherein, The fifth die comprises a fifth die seat, the fifth die seat is provided with a third clamping block and a fourth clamping block below the third clamping block, the third clamping block and the fourth clamping block can clamp and position the area around the boss, and the fifth die seat is further provided with a stretching punch, the stretching punch can move up and pass through the center hole to stretch the boss with the center hole into a cylinder.

7. The harmonic reducer flexspline initial forming machining transfer mold of claim 1, wherein, The sixth die comprises a sixth die seat provided with a supporting block, a third sizing concave die and a sizing pressing block, the supporting block is used for supporting the material sheet, the inner contour of the third sizing concave die is matched with the outer contour of the cylinder body, and the sizing pressing block is arranged in the third sizing concave die in a lifting manner. The third sizing concave die presses the area around the cylinder body downward, and the sizing pressing block presses the cylinder body downward to compress and shape the R angle of the flange connection position of the cylinder body.

8. The harmonic reducer flexspline initial forming machining transfer mold according to claim 7, characterized in that, The sixth die seat is provided with a hydraulic top rod and an inner diameter protection punch matched with the inner contour of the cylinder body, the hydraulic top rod drives the sizing pressing block to move up and down, and the inner diameter protection punch is inserted into the cylinder body when the R angle is compressed and shaped by the third sizing concave die and the sizing pressing block, so as to support the wall of the cylinder body.

9. The harmonic reducer flexspline initial forming machining transfer mold of claim 1, wherein, The seventh die comprises a seventh die seat and a first inner lining block, the seventh die seat is provided with a flange hole punch, a fifth clamping block and a sixth clamping block located below the fifth clamping block, the fifth clamping block and the sixth clamping block can clamp and position the area around the cylinder body, and the flange hole punch moves to punch a flange hole around the cylinder body; the first inner lining block can support the wall of the cylinder body in the cylinder body.

10. The harmonic reducer flexspline initial forming machining transfer mold of claim 1, wherein, The eighth die comprises an eighth die seat and a second inner lining block, the eighth die seat is provided with a trimming punch, a seventh clamping block and an eighth clamping block located below the seventh clamping block, the seventh clamping block and the eighth clamping block can clamp and position the area around the cylinder body, and the trimming punch moves to punch a flange around the cylinder body; the second inner lining block can support the wall of the cylinder body in the cylinder body.

Images