Method and apparatus for manufacturing toothed rotating components with thickened tooth flanks

Abstract

Method for manufacturing a toothed and rotating component (10) with thickened tooth flanks (6, 12), comprising the following steps: a) Production of teeth (3) distributed evenly around the circumference on a blank (1) extending along a plane made of sheet material, wherein the individual teeth (3) have lateral tooth flanks (6) which are spaced apart from each other by cutouts (4) distributed around the circumference of the blank (1); characterized by the following steps: b) Deformation of at least one tooth flank (6) to produce at least one materially uniform flap (5) projecting from the plane of the blank (1), which projects obliquely or vertically upwards from the plane of the blank (1); and that this deformation is carried out by means of a die (17) which presses the blank (1) onto a complementary die (18) arranged opposite the die (17), and that the flaps (5) of the blank (1) are formed by an extrusion process; c) Deformation of the protruding flap (5) towards the plane of the blank (1) to thicken (9) the teeth (3) in the area of ​​the original tooth flanks (6).

Description

[0001] The invention relates to a method for manufacturing toothed and rotating components with thickened tooth flanks and a component manufactured according to the method according to the preamble of the independent patent claims.

[0002] Toothed rotating components are used in a wide range of applications in mechanical engineering. For example, gears for two-wheeled vehicles are manufactured with thickened tooth flanks. It is known to have a thickened tooth flank on one side of a tooth, while the following tooth does not have such a thickening. This alternating thickening, with the next tooth lacking it, serves, for example, in a bicycle chain drive, to ensure that the chain, with a wider link, centers itself on the thickened tooth flank, while the following narrower link is also centered on the unthickened tooth flank.

[0003] This method is therefore used to center chain drives on a sprocket or chainring of a two-wheeled vehicle. However, this known technique does not increase the load-bearing capacity of the toothed and rotating components.

[0004] EP1 721 821 B1 describes a sprocket for a two-wheeled vehicle in which the sprocket teeth are reinforced and doubled with additional elements, but this does not involve any material deformation. It is therefore a reinforcement of the tooth flank of the sprocket teeth by add-on components, without any metallic deformation taking place. Consequently, the load transmission through such a multi-part sprocket with a composite tooth is unsatisfactory.

[0005] US Patent 4,071,127 A discloses a method for manufacturing a toothed and rotating component with thickened tooth flanks, comprising the following steps: a) Production of teeth evenly distributed around the circumference with lateral flaps of uniform material, on a blank made of sheet metal extending along a plane, wherein the teeth are spaced apart from each other by cutouts distributed around the circumference of the blank; b) Deformation of the lobes so that they protrude from the plane of the blank; c) Subsequent deformation of the protruding lobes towards the plane of the blank to thicken the teeth and form reinforced tooth flanks.

[0006] A disadvantage of this method, however, is that the teeth with the lateral flaps must first be manufactured, e.g., stamped, and only then are the flaps bent over to thicken them. Therefore, increasing the thickness of the tooth flanks is insufficient to provide the necessary strength for high-stress applications.

[0007] The invention is therefore based on the objective of proposing a method for manufacturing a toothed rotating component in which the bearing area of ​​the tooth flank is substantially increased, and furthermore a device for manufacturing such a component, which is characterized by the advantage of high load transmission.

[0008] To solve the problem posed, the invention is characterized by a method according to the features of the technical teaching of claim 1 and claim 9, while advantageous embodiments and further developments of the invention can be found in the dependent claims.

[0009] A preferred component manufactured according to the method is therefore also the subject of the invention.

[0010] The advantage of the invention is that a material-intrinsic forming process takes place in the area of ​​the tooth flanks of a blank, which is preferably a sheet metal blank, and that this forming process is carried out in a cold extrusion process, which has the advantage that a material structure is achieved in the cold extrusion process which undergoes a crystalline forming process and thus results in increased strength in the area of ​​the tooth flank processed in this way.

[0011] The present procedure consists of the following procedural steps: 1. Preparation of a blank made of sheet metal material with the attachment of teeth evenly distributed around the circumference, which are separated from each other by conical or circular cutouts. 2. Deformation of the prepared blank after process step 1 in such a way that the tooth flanks of the blank from the first process step are deformed upwards or downwards at an angle to the plane of the blank in such a way that they protrude obliquely or vertically upwards or downwards from the plane of the blank. 3. In the third process step, the upwardly or downwardly angled or vertically protruding tooth flanks are reshaped so that they lie above the initial sheet thickness and form the back of the tooth flank in order to achieve a thickening thickness that is above the initial sheet thickness. 4. In a final process step, it is then provided that the gear geometry is recut with a suitable tool, this tool preferably being designed as a punching tool.

[0012] In a preferred embodiment, it is provided that, with an initial sheet thickness in the range of approximately 1-10 mm, the tooth flank back is thickened by 10-40% of the initial sheet thickness.

[0013] This technical teaching achieves the significant advantage that the load-bearing capacity of such a rotating component, which is preferably designed as a gear, is substantially increased because the thickening of the tooth flanks can optionally take place either on one side of the tooth flank or on both sides of the tooth flank.

[0014] By reshaping the initially raised tooth flank flaps back into the plane of the blank itself, the advantage is achieved that the folded-over flaps reinforce the tooth flank and are joined with the original material of the blank in a subsequent embossing process using cold extrusion, resulting in superior material properties in the area of ​​the thickened tooth flanks.

[0015] The advantage of this method is that the thickening only occurs in the area of ​​the tooth flanks themselves, that is, in the area between the tooth tip and the tooth root. Since the thickening takes place only in the area of ​​the tooth flanks, the load-bearing capacity of even relatively thin, rotating components can be significantly increased, as only the load-bearing tooth flanks are thickened, while the remaining parts of the blank can be kept narrow and thin, since load transmission does not essentially occur via these other parts.

[0016] Instead of recutting with a punching tool, other recutting tools can also be used, such as chip-removing tools like milling cutters, drills or countersinking tools.

[0017] However, in the present invention, a pressing tool is preferred for producing the original tooth geometry.

[0018] The invention is not limited to the manufacture of gears. It generally concerns the manufacture of toothed, rotating components, with gears being of particular importance. These gears are preferably used as chainrings or sprockets for bicycles.

[0019] However, such gears are also suitable for camshaft drives for internal combustion engines or for transmissions of electric vehicles or internal combustion vehicles.

[0020] Such toothed rotating components are also used as multi-plate gears, which are installed in multi-plate clutches of gearboxes, wherein the toothed multi-plate gear with the thickened tooth flanks according to the invention cooperates with a multi-plate carrier in the gearbox.

[0021] In all applications, it may be possible to provide for a one-sided thickening of the tooth flank or a two-sided thickening of the tooth flank according to the inventive method.

[0022] For forming, dies, forming punches, and part lifters are preferably used. The die, by means of a ram, presses the component past the forming punches distributed around its circumference, whereby the material to the left and right of the forming punches is folded over, creating a material thickening between the die and the forming punches. The counter-holder is spring-loaded and serves to keep the component flat and to strip it from the forming punches after forming.

[0023] For further processing by means of embossing, a die, a matrix and a blank holder are preferably used.

[0024] The hold-down device first presses the component onto the die using spring force. The die, rigidly mounted in the upper part, then compresses the material downwards during the pressing motion. Because the die is designed with a barrier chamfer to prevent the material from flowing towards the center of the die, a thickening occurs in the opposite direction.

[0025] The next manufacturing step involves using a punching tool to recut the entire gear geometry, resulting in a flank thickness that is increased compared to the original sheet thickness.

[0026] In the case of multi-plate clutches, it is preferred to thicken the tooth flanks on both sides in order to significantly increase the load transmission torques in such multi-plate clutches.

[0027] This achieves the further advantage of providing a higher load-bearing capacity for the multi-plate gear, since narrower multi-plate gears can be used overall with regard to the load transmission of the multi-plate clutch, and the resulting gearbox can be built shorter.

[0028] The basic idea of ​​the process is the partial thickening of the tooth flanks by means of a multi-stage forming process in order to maximize the contact surfaces for force transmission with a comparatively thin starting material thickness.

[0029] This is therefore a process for manufacturing a toothed and rotating component with thickened tooth flanks, which comprises the following steps: a) Production of teeth evenly distributed around the circumference on a blank extending along a plane made of sheet metal material, wherein the individual teeth have lateral tooth flanks which are spaced apart from each other by cutouts distributed around the circumference of the blank; b) Deformation of at least one tooth flank to produce at least one material-uniform flap projecting from the plane of the blank, which projects obliquely or vertically upwards from the plane of the blank; c) Deformation of the protruding flap towards the plane of the blank to thicken the teeth in the area of ​​the original tooth flanks.

[0030] Preferably, in a further step d), the gear geometry is recut using a punching tool.

[0031] The deformation according to step b) is carried out by means of a die that presses the blank onto a complementary die arranged opposite the die, whereby the lobes of the blank are formed in a flow pressing process.

[0032] The die has uniformly distributed die teeth around its circumference, wherein at least one die tooth of the die deforms the material of the tooth flanks of the blank at least partially into the at least one flap on the blank, the flap being laterally pressed against the die teeth of the die engaging between the die teeth of the die in a flow pressing process.

[0033] In step c), at least one flap is deformed back to the plane of the blank by means of an embossing die in order to achieve a thickening of the tooth flank.

[0034] Preferably, both lateral tooth flanks of a tooth are reshaped to thicken the tooth flank.

[0035] The forming process according to at least one of steps c) and d) is preferably a flow forming process, in particular a cold flow forming process.

[0036] In summary, the device according to the invention for producing a toothed and rotating component with thickened tooth flanks from a blank comprises a forming tool for exerting a forming force on at least one tooth flank to displace the material of the blank at this point to produce at least one flap protruding from the plane of the blank, and a stamping die that deforms the flap back towards the plane of the blank. The forming tool includes at least one die pressing onto the blank with forming teeth arranged on its outer circumference, and a die arranged opposite the die with complementary forming teeth or forming rollers that deforms the at least one flap of the blank.

[0037] In another embodiment, the method is for manufacturing a milling tool as a rotating cutting tool for milling. The tool has at least one, but usually several, cutting edges, which are generally referred to as cutting edges. The tool is used on milling machines and machining centers, and the cutting edges can cut material perpendicular or at an angle to the axis of rotation.

[0038] Most well-known milling cutters are made entirely of high-speed steel or carbide; some instead have a steel body and screwed-in or clamped indexable inserts. These can also be made of carbide or of the significantly harder cutting ceramics.

[0039] However, the use of an indexable insert can be dispensed with by another method of the invention, which provides for the production of thickened cutting edges. This method comprises the following steps: a) Production of cutting edges evenly distributed around the circumference of a blank made of a hard material extending along a plane, wherein the individual cutting edges have lateral cutting flanks which are spaced apart from each other by cutouts distributed around the circumference of the blank; b) Deformation of at least one cutting edge to produce at least one material-uniform flap projecting from the plane of the blank, which projects obliquely or vertically upwards from the plane of the blank; c) Deformation of the protruding flap towards the plane of the blank to thicken the cutting edge in the area of ​​the original cutting flanks.

[0040] Preferably, in a subsequent step d), the thickened area is then ground. This grinding process allows the final cutting geometry of the cutting edges distributed around the circumference to be created. For example, the rake angle and clearance angle of the cutting edges can be determined.

[0041] However, the invention is not limited to grinding and claims any mechanical surface treatment.

[0042] This method for manufacturing a milling tool now makes it possible to optimize the contact surfaces for force transmission from a comparatively thin starting material thickness.

[0043] The blank is made of materials such as high-speed steel, carbide, or cermet. A hardenable sheet metal material with a Rockwell hardness of 45 HRC is preferred. Such a milling cutter is used, for example, in woodworking or plastics processing.

[0044] The subject matter of the present invention is not only derived from the subject matter of the individual patent claims, but also from the combination of the individual patent claims with one another.

[0045] All information and features disclosed in the documents, including the abstract, and in particular the spatial configuration shown in the drawings, could be claimed as essential to the invention, insofar as they are novel individually or in combination compared to the prior art. The use of the terms "essential," "inventive," or "essential to the invention" is subjective and does not imply that the features so designated must necessarily be part of one or more patent claims.

[0046] The invention is explained in more detail below with reference to drawings illustrating only one embodiment. Further essential features and advantages of the invention will become apparent from the drawings and their description.

[0047] They show: Fig. 1a - 1e: The step-by-step processing of a blank during the execution of the inventive method Fig. 2: An enlarged perspective view of the tooth geometry after completion Fig. 3: The perspective view of a matrix in conjunction with a forming tool for producing the tooth geometry according to the invention. Fig. 4: The section through the arrangement according to Fig. 3 Fig. 5: A perspective view of the die and forming die during the processing of the blank in the process step after Fig. 1b Fig. 6: The enlarged view of the Fig. 5 with further details Fig. 7: The schematic representation of the forming process on a blank, which is shown as a sheet metal blank for better clarity. Fig. 8: The procedural step after Fig. 7 with the embossing of the formed sheet metal flap Fig. 9: The highly formed sheet metal flap, in its undeformed state after Fig. 7 Fig. 10: The embossed, reshaped flap after the embossing process according to Fig. 8 Fig. 11: An embossing tool in perspective view consisting of a blank holder and an embossing die arranged in the blank holder Fig. 12: The section through the arrangement in Fig. 11 Fig. 13: The perspective view of the embossing process of the reshaped flaps 5, 5' with the embossing tool according to Fig. 11 and Fig. 12 Fig. 14' An enlarged view of the Fig. 13 with further details Fig. 15: The perspective view of an embossing die Fig. 16: An alternative to the forming tool according to the previous figures, in the form of a roller stamp. Fig. 17: Section through the arrangement according to Fig. 16 Fig. 18: A detailed illustration of the use of a roller stamp Fig. 19: A perspective view of a disc cutter Fig. 20: Another embodiment of a disc cutter in top view

[0048] In Fig. Figure 1a shows a blank 1 of a general type, represented as a sheet metal blank, which has an arbitrary diameter in the range of 50-300 mm. Its preferred sheet thickness is approximately in the range of 1-10 mm, whereby a sheet thickness of 2 mm is used in the embodiment shown here. The blank 1 is rotatable in the central axis 2 and has a number of teeth 3 evenly distributed around its circumference, which are separated from each other by conical cutouts 4 pointing towards the center of the sheet metal blank.

[0049] According to the invention, the first process step of forming the tooth flanks is carried out according to Fig. 1b by using the forming tools 16, 17, 18 shown later to deform the lateral tooth flanks in such a way that the lobes 5 are pushed upwards from the tooth flanks and thus protrude from the plane of the blank 1, preferably in a vertical direction, which in Fig. 1b is shown. The flaps 5 thus pressed out of the plane of the blank 1 are in the next process step according to Fig. 1c is bent over. This is done by an embossing process, so that the upturned flaps 5 now become the bent-over flaps 5', which are pressed back towards the plane of the blank 1, but protrude above the plane to form the thickened flanks 12 described later. Thus, a forming process takes place in the area of ​​the tooth flanks 6 on the blank 1, whereby the blank 1' after Fig. 1b describes the forming process while the blank 1" after Fig. 1c shows the embossing process.

[0050] Finally, in the next procedural step, after Fig. 1d a finished trim, so that now a finished blank 1''' after Fig. 1d is present. This final trimming ultimately results in the finished toothed component with thickened tooth flanks due to the flaps 5 formed and thickened in the thickening process.

[0051] The flaps 5' after the embossing process are thickened using a flow-forming process and formed onto the respective tooth 3, while the subsequently bent flap 5" corresponds to the desired tooth flank geometry of the component through final trimming. Finally, the following is obtained in Fig. 1e shows a finished, toothed, rotating component with thickened tooth flanks. The detail circle in Fig. Figure 1e now shows the details of the reshaped tooth flanks according to Fig. 2.

[0052] The Fig. Figure 2 shows that the cutouts 4 are now present in the sheet metal material 8 of the blank 1 and that the teeth are formed in the area of ​​tooth head 14 and tooth base 15 and that the thickened tooth flanks result between these two parts 14, 15, which show the thickenings 9.

[0053] In the illustrated embodiment, the thickening 9 is shown as complete, which means that from the initial sheet thickness 11 of the toothed component 10 a thickening thickness 13 has now been achieved at the thickened flanks 12.

[0054] The principle of the present procedure can be explained by the Fig. 2 will be explained by replacing the previous raised flap 5 after the procedure step Fig. 1b has now been folded over in the direction of arrow 35 and, as a folded flap, now covers the tooth flank and is formed on the tooth flank in a cold extrusion process with a subsequent embossing process according to process step c), without any material separation occurring. This is therefore a one-piece forming process, which means that the material of the raised flap 5 is formed in one piece on the undeformed tooth flank and bonded to the tooth flank in a cold extrusion process, so that a material-uniform composite is formed.

[0055] The cold extrusion process results in a crystalline deformation, which ensures that the bent flaps bond with the tooth flank in a single piece and with uniform material composition through the subsequent embossing process.

[0056] However, the invention is not limited to this. In a different and less efficient embodiment, it can be provided that only the flap 5 is bent in the direction of arrow 35, and the subsequent embossing process takes place with such a embossing thickness that cold extrusion of the bent flap 5 with the underlying tooth flank 6 does not occur. This means that the flap 5 lies only above the tooth flank 6 without forming a single material bond.

[0057] This less efficient embodiment should also be covered by the scope of protection of the invention.

[0058] The Fig. Figures 3 to 5 show the way the tooth flank 5 is shaped, which is raised with the tool shown here.

[0059] The tool is a forming tool and consists of an inner central die 17, which has a number of cutouts 19 on its outer circumference, between which the forming teeth 20 are arranged. The number of forming teeth corresponds to the number of teeth 3 in the blank 1.

[0060] A forming die 18 is arranged at a distance from the inner matrix 17, which surrounds the circumference of the inner matrix 17 at a distance, wherein this forming die 18 consists of a plurality of forming teeth 21, between which the associated tooth gaps 22 are arranged.

[0061] This in the Fig. The forming tool 16 mentioned in 3-5 therefore consists of the die 17 and the forming punch 18 arranged on the outer circumference of the die.

[0062] The Fig. 4 shows the same situation as the Fig. 3 on average.

[0063] The Fig. Figure 5 shows that with the two interlocking tools 17, 18 the flap 5 can now be bent out of the tooth flank 6 and thus protrude vertically upwards from the plane of the blank 1, as shown in Fig. 5 is shown. The undeformed tooth flank 6 is therefore shown in dashed lines and transitions into the raised lobe 5, using the forming tool 16 according to Fig. 3 and Fig. 4.

[0064] A shaped tooth 21 is used, the structure and function of which will be described later.

[0065] In Fig. 6 is the magnification according to Fig. 5 is shown, where it can be seen that a form tooth 21 highlighted in the drawing from the form stamp 18 causes the flap 5 to be raised, with the undeformed tooth flank 6 again being shown with dashed lines and this tooth flank finally being folded up on one side, as shown in Fig. 2 is shown with the arrow direction 35.

[0066] Out of Fig. Figure 6 shows that a counterholder 23 is present, which corresponds to the shape of the blank 1 and which has a number of forming teeth 24 that correspond to and are opposite the forming teeth 20 of the matrix 17.

[0067] It is also shown that the counterholder 23 has a spring 29 from below in order to form a resilient counter-bearing against the rigid die 17, which moves downwards in the direction of arrow 26 with a pressing motion and is arranged in the upper part of the tool 28. The counterholder 23 is therefore arranged in the lower part of the tool 27.

[0068] The cutouts 25 in the counterholder 23 correspond to the cutouts 19 in the die 17. From the Fig. It can also be seen from section 6 that the originally undeformed tooth flanks 6 are now deformed by the forming process according to Fig. 6 are folded upwards to form the flaps 5.

[0069] The Fig. Figures 7 to 10 illustrate the forming process using an example, although for the sake of clarity, this example does not show the forming process on a toothed blank, as is the case, for example, in Fig. 1 is shown, but on a sheet metal blank 30, which, however, has the same properties as the toothed blank 1.

[0070] In Fig. 7 it can be seen that in the case of the blank 1', which after the process step Fig. 1d corresponds to a cutout 31, on which a flap 5 has already been formed upwards by the rising forming tooth 21, so that the flap 5 has been formed in the blank 1'.

[0071] The Fig. Figure 8 shows the reshaping of the flap 5 into the flap 5' with a suitable embossing die 32, which has a form slope 33 on its embossing surface, which is applied to the raised flap 5. Fig. 7 runs up and compresses it downwards in the direction of arrow 34 in order to bend it over. The flap 5' now lies raised on the surface of the sheet metal plate 30, as shown in Fig. 10 is shown.

[0072] This embossing process takes place – as described above – as a cold flow pressing process, which means that a one-piece bond of the flap 5 occurs during the folding and embossing of the flap 5' onto the plane of the sheet metal blank 30, as is also the case in Fig. 10 is shown.

[0073] The Fig. Figures 11 to 13 show a suitable embossing tool, which allows for re-embossing according to the Fig. 8 to 10 accomplished. It essentially consists of a hold-down device 36 arranged on the outer circumference, in which a number of stamping dies 32 are arranged centrally, corresponding to the tooth geometry of the toothed component 10.

[0074] The embossing tool has a number of 32 embossing dies, as shown in Fig. 13 shown. Each embossing die is suitable for the raised flap 5, as shown in Fig. 13 is to be transformed into a bent-down, i.e., folded-over, flap 5', as shown in Fig. 13 is shown. This means that the one in Fig. Blank 1" shown in 1c was produced.

[0075] The Fig. Figure 14 shows an enlarged view of the Fig. Figure 13 provides further details. First, it is shown that the embossing die 32 is rigidly arranged in the upper part of the tool 28 and that the hold-down device 36 is spring-loaded in the direction of arrow 37. This results in the hold-down device 36 closing the gap 43, as shown in Fig. 2, between the thickened tooth flanks 9. The embossing punch 32 moves downwards in the direction of arrow 26 with the pressing movement, whereby the die 17 is held rigidly in the lower part of the tool 27.

[0076] The special shape of the embossing die 32 used, with a slope 33 and an associated radius surface 40, is described by means of Fig. 15 explained.

[0077] The embossing die 32 moves downwards in the direction of arrow 26 and has a laterally angled draft angle 33, which ensures that the raised material of the flap 5 is deformed back in the direction of arrow 35, resulting in an angle 42 between the vertical and the plane of the draft angle 33.

[0078] The draft angle 33 is bounded upwards by a perpendicularly extending compression surface 38, which, when the stamping die 32 is lowered, ensures that the flap 5, which bends downwards in the direction of arrow 35, is firmly bonded to the material of the blank 1 in the flow-forming process, thus forming a homogeneous composite. The draft angle 33 is arranged on one side as a recess 41 in the stamping die 32 and transitions into the edge region with a suitable radius surface 40. The radius surface forms the transition of the thickened flank 12 into the undeformed sheet material.

[0079] With the first embodiment shown according to the Fig. For teeth 1 to 15, a superior tooth geometry is achieved through the thickened tooth flanks, which was not possible before.

[0080] The exemplary embodiment according to the Fig. Figures 16 to 18 show another alternative, in which a roll forming tool is used in the forming process step shown here. This tool essentially consists of a plurality of roll punches 48 arranged on the outer circumference of the previously described die 17. These punches are arranged so that their forming surfaces and the associated forming rollers 50 move into the cutouts 19 of the die 17 in order to perform the same forming process on the blank 1'. For the Fig. Therefore, the same explanations apply to section 18 as those given for the shaped tooth 21 in Fig. 6 were given. Fig. Figure 18 further shows that the respective forming roller 50 is rotatably mounted and has the necessary forming surfaces on its outer circumference.

[0081] The method according to the invention thus achieves superior load-bearing properties for rotating toothed components.

[0082] The Fig. Figure 19 shows that the cutouts 54 are now present in the sheet metal material 58 of a blank and the teeth 53 show the thickenings 59.

[0083] In the illustrated embodiment, the thickening 59 is shown as complete, which means that a thickening thickness 57 has now been achieved at the thickened cutting edges 56 from the initial sheet thickness of the disc cutter 60.

[0084] This is therefore a one-piece forming process, which means that the material of the raised flap 55 is formed in one piece on the undeformed cutting edge and joined to the cutting edge in a cold extrusion process, so that a material-uniform composite is formed.

[0085] The cold extrusion process results in a crystalline forming process, which ensures that the bent flaps bond with the cutting edge in a single piece and with uniform material composition through the subsequent embossing process.

[0086] However, the invention is not limited to this. In a different and less efficient embodiment, it can be provided that only the flap 55 is bent over, and the subsequent embossing process takes place with such a embossing thickness that cold extrusion of the bent flap 55 with the underlying cutting edge 56 does not occur. This means that the flap 55 lies only above the cutting edge 56 without forming a single material bond.

[0087] In Fig. Figure 20 shows a general blank 51 in the lower half, a sheet metal blank with an arbitrary diameter in the range of 50-300 mm. Its preferred sheet thickness is approximately in the range of 1-10 mm, with a sheet thickness of 2 mm being used in the embodiment shown here. The blank 51 is rotatable on the central axis 52 and, as shown in the upper half, has a number of teeth 53 evenly distributed around its circumference, separated from each other by cutouts 54 pointing towards the center of the sheet metal blank.

[0088] In the embodiment for manufacturing a disc milling cutter 60, the first process step of forming the cutting edges 56 is also carried out by using a forming tool to deform the lateral cutting edges 56 such that the lobes of the cutting edges 56 are pushed upwards and thus protrude from the plane of the blank 51. In the next process step, the lobes thus pushed out of the plane of the blank 51 are bent over. This is done by an embossing process, so that the bent lobes now become bent lobes, which are pushed back towards the plane of the blank 51, but protrude above the plane to form the thickened cutting edges 56 described later. Thus, a forming process takes place in the area of ​​the cutting edges on the blank 51.

[0089] Finally, in the next process step, mechanical processing takes place, e.g. grinding, so that a finished disc milling cutter is now available. Fig. 20. This processing ultimately results in the finished disc cutter with thickened cutting edges due to the flaps 55 formed and thickened in the thickening process.

[0090] The previously formed flaps are thickened after the embossing process in the flow pressing process and formed onto the respective tooth 53, while the later bent flap 55 corresponds to the desired cutting flank geometry of the component by grinding.

[0091] Thus, the inventive method for thickening a tooth of a toothed component can be applied to gears as well as to disc milling cutters. This always involves deformation of at least one tooth flank or cutting edge to produce at least one uniform flap of material projecting from the plane of a blank, which protrudes obliquely or vertically upwards from the plane of the blank. In a subsequent process step, the projecting flap is deformed towards the plane of the blank to thicken the teeth in the area of ​​the original tooth flanks.

[0092] The process for manufacturing a disc cutter is the same as the process for manufacturing a generally toothed component, which is exemplified in the description as a gear. Therefore, the tools and process steps used for the gear, with the reference numerals shown in the figures, are also applicable to a disc cutter. Drawing legend 1, 1', 1'', 1''' blank 2 Center axis 3 teeth 4 Excerpt 5, 5', 5'' flaps (lateral) 6 Tooth flank 7 Arrow direction 8 Sheet metal material 9 Thickening 10 component, toothed 11 Initial sheet thickness 12 flanks, thickened 13 Thickening strength 14 Tooth head 15 Tooth base 16 forming tools 17 die 18 stamp shapes 19 excerpt (in 17) 20 shaped teeth (out of 17) 21st shaped tooth (out of 18) 22 tooth gaps 23 Counterholds 24 shaped teeth (out of 24) 25 excerpts (in 24) 26 Arrow direction 27 Tool base 28 Tool top 29 Suspension 30 sheet metal plates 31 excerpt (in 30) 32 embossing dies 33 Draft angle (32) 34 Arrow direction 35 Arrow direction 36 hold-down devices 37 Arrow direction (spring-loaded) 38 compression area (out of 32) 39 feet (out of 32) 40 radius area (out of 32) 41 Exclusion (in 32) 42 angles (in 41) 43 Gap 48 roller stamps 49 50 Form roll (of 48) 51 blanks 52 Center axis 53 teeth 54 Excerpt 55 rags 56 cutting edge 57 Thickening strength 58 Sheet metal material 59 Thickening 60 disc cutters

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