DEVICE AND METHOD FOR COLD FORMING PROFILING WORKPIECES

Description

[0001] The invention relates to the field of producing profiles, particularly by cold forming, for example in rotationally symmetric solid or hollow parts. It relates to devices and methods according to the generic terms of the patent claims.

[0002] Various methods for cold forming solid or hollow parts are known from the state of the art.

[0003] For example, it is known to profile hollow parts in a single step by forming an unprofiled sheet metal part using a device that has a plurality of tools distributed over a circumference. When the sheet metal part is inserted into the device, these tools engage the sheet metal part where profile gaps are to be created. A corresponding method for producing an internally and / or externally toothed cup-shaped sheet metal part with teeth extending toward the cup's central axis is known, for example, from DE102014002971A1.

[0004] The disadvantage of such processes is that they are very inflexible because, for example, a change in the profile gap shape requires the replacement of all tools and a change to machining sheet metal parts with a different diameter requires the creation of a new, appropriately adapted device.

[0005] In other cold forming processes, workpieces are periodically hammered by rotating tools to create a profile, as is known, for example, from WO 2005 / 075125 A1. This process is very flexible in use because it can be adapted to other products or changed product specifications with very little effort. Furthermore, the process enables the creation of very long profiles, even if this requires significant material deformation, such as for gears with a large module in solid material. On the other hand, continuing a profile close to a shoulder that projects radially outwards is not easily possible with the process known from WO 2005 / 075125 A1 due to the rotating motion of the tools.

[0006] A method that allows a profile to be created in a workpiece up to close to an outwardly projecting shoulder of the workpiece is known, for example, from WO 2007 / 009267 A1. In the method described therein, a cylindrical, thin-walled hollow part, which sits on an externally profiled mandrel, is cold-formed with a profile running essentially parallel to the longitudinal axis of the hollow part. At least one profiling tool is suddenly hammered onto the hollow part from the outside, radially to the longitudinal axis of the hollow part. The profiling tool is oscillated in a direction perpendicular to the longitudinal axis, i.e., by a radial, linear back-and-forth movement on the surface of the hollow part.And the profiling tool is moved axially relative to the hollow part at a constant radial infeed depth until the desired profile length is reached, whereby the machining of the hollow part can be started at an outwardly projecting shoulder of the hollow part.

[0007] If particularly high demands are placed on the surface quality, it may be necessary to carry out post-processing of the hollow part following the process according to WO 2007 / 009267 A1, because the hollow part is only machined in a short axial section by the profiling tool during each operation, which may result in a slight, flaky roughness.

[0008] Furthermore, WO 2020 / 099536, which forms the basis for the preamble of the independent claims, discloses a method that enables the creation of profiles extending very close to a shoulder that projects radially outward. This method makes it possible to create profiles even when this requires significant material deformation, for example, in the case of gears with a large module, especially in solid material. Furthermore, the method can achieve a high surface quality that generally does not require any post-processing. However, at least in solid material, the length of profiles created in this way is quite limited, especially when high precision requirements are placed on the profile.

[0009] It is an object of the invention to provide methods for producing a profiled body provided with a profiling and corresponding devices which do not have the disadvantages mentioned above.

[0010] For example, it should be possible to easily and cost-effectively convert the process or device for the production of other products or for the realization of changed product specifications.

[0011] A further possible object of the invention is to enable profile creation with particularly high surface quality.

[0012] A further possible object of the invention is to produce profiles of great length, in particular in profiles that require significant material deformation, such as gears with a large module, in particular in solid material.

[0013] A further possible object of the invention is to enable particularly precise profiling, in particular in solid material and with large profiling lengths.

[0014] A further possible object of the invention is to enable profile creation with particularly high productivity.

[0015] A further possible object of the invention is to enable profiling close to a workpiece projection, for example close to an outwardly projecting shoulder of the workpiece to be profiled.

[0016] A further possible object of the invention is to enable profiling between two profiling limiting structures and up to close to them.

[0017] At least one of these objects can be achieved by devices and / or methods described below.

[0018] In the method, a tool holder and, with it, a tool held by the tool holder are driven to perform a complex movement comprising at least two components: a revolving movement, for example, along an orbit similar to a planetary axis, and a rotational movement around its own axis. These two movements are synchronized with each other. The revolving movement can be a periodic movement. A corresponding drive device can be provided to generate the rotational movement.

[0019] Due to the rotating movement, the tool holder and thus also the tool can be periodically brought towards a workpiece to be machined and have a forming effect on it and then move away from the workpiece again in order to then approach it again and so on. For example, the tool can be brought into forming engagement with the workpiece once per revolution (or every second or every third revolution).

[0020] By providing a rotational movement of a tool axis around the rotational axis of the tool holder, together with the orbital movement of the tool holder, as explained in more detail below, the tool can repeatedly cold-form the workpiece in a novel manner. The tool can have an effective area that repeatedly machines the workpiece in a machining area of ​​the workpiece. In this case, a direction of rotation of the tool holder around the rotational axis can, in particular, be opposite to a direction of rotation of the orbital movement.

[0021] Although similar to the method of WO 2005 / 075125 A1, important differences arise between the methods due to the difference between the tool axis and the tool holder rotation axis (which are identical in WO 2005 / 075125 A1), as will become clear below.

[0022] Thus, the tool can periodically engage the workpiece (due to the orbital motion) for a short period of time. Within this short period of time, in which the tool (more precisely: the effective area of ​​the tool) is in contact with the workpiece, the tool rotates not only around the tool axis, if applicable, but also around the rotational axis of the tool holder, so that (during the aforementioned short period of time), in addition to the orbital motion imparted by the tool holder, a movement of the tool occurs that may be opposite to the orbital motion. Thus, the length of a contact area in which the effective area of ​​the tool is in contact with the workpiece during a forming operation can be shorter than would be the case with the method according to the aforementioned WO 2005 / 075125 A1.Furthermore, this is clearly different from non-hammering but rolling machining, as known, for example, from the aforementioned WO 2020 / 099536.

[0023] The machining of the workpiece to create the profile consists of a multitude of individual machining steps, axially offset from one another along the axial profile extension, which overlap only slightly. This allows for high surface quality and, above all, high profiling precision. Accordingly, post-processing, as may be necessary in the case of the process according to WO 2007 / 009267 A1 when particularly high surface quality requirements are met, can be avoided.

[0024] And through the rotational movement of the tool holder around its own axis, together with the aforementioned synchronization, it is possible to ensure that the tool holder is always in a desired or predetermined azimuthal orientation when the tool is brought into engagement with the workpiece, for example, always in the same azimuthal orientation. Due to the aforementioned rotational movement, the azimuthal orientation of the tool holder changes during each engagement; over the duration of the engagement, the azimuthal orientation changes in the same way, for example, with each tool engagement.

[0025] For example, the rotary movement of the tool holder can be synchronized with the rotating movement of the tool holder in such a way that the tool holder passes through the same azimuthal orientations during each of the forming operations.

[0026] In this text, the terms azimuth and azimuthal refer to the axis of rotation of the tool holder, unless otherwise stated.

[0027] Synchronization enables the effective use of a tool that is mounted for rotation about a tool axis that is different from the aforementioned rotation axis. In particular, a tool with a rotationally symmetrical effective range can be used. The tool can thus be, for example, a rolling roller, as known from the aforementioned WO 2005 / 075125 A1.

[0028] Due to the self-rotation of the tool holder around its axis of rotation, while the tool axis rotates around the axis of rotation, the tool can move away from the workpiece relatively quickly after engagement, so that contact with a workpiece projection, for example a workpiece shoulder, can be avoided, and thus deformation of the workpiece projection by the tool can be avoided.

[0029] In order to achieve a desired axial extension of the profiling, an axial feed of the workpiece can be provided.

[0030] The rotary motion can, for example, occur throughout the entire rotation or continuously. This allows for good synchronization of the tool holder's rotary motion with its rotary motion.

[0031] For example, the synchronization of the two movements can be achieved mechanically. A mechanical synchronization device can be provided for this synchronization. However, the aforementioned movements can also be synchronized with each other in other ways, for example, electronically, i.e., by an electronic synchronization device.

[0032] In some embodiments, the synchronization device, also referred to below as the second synchronization device, comprises a planetary gear. For example, it may comprise a ring gear and a planetary gear running within the ring gear. The planetary gear may be part of the tool holder or at least be rigidly connected to the tool holder or rotate with the rotational movement of the tool holder about the rotational axis and also participate in the aforementioned orbital movement. The axis of the planetary gear may be coaxial with the rotational axis.

[0033] On the other hand, the planetary gear can also drive the tool holder to rotate about its axis of rotation. The drive device mentioned above for generating the rotational movement of the tool holder about its axis of rotation can therefore comprise a planetary gear.

[0034] Thus, a planetary gear can be provided which simultaneously generates the rotary movement of the tool holder about its axis of rotation and synchronizes this rotary movement with the rotating movement of the tool holder.

[0035] The aforementioned, for example, planetary-like orbital motion can be imparted to the tool holder by a revolving body. The tool holder can be mounted in the revolving body, in particular, mounted so as to be rotatable about its axis of rotation. The revolving body can, for example, rotate about a revolving body axis, and the axis of rotation of the tool holder is spaced from the revolving body axis, so that the axis of rotation performs an orbital movement essentially along a circular path.

[0036] This orbital movement can, if the aforementioned planetary gear is provided, generate the rotational movement of the workpiece holder, mediated by the planetary gear. For this purpose, the orbital axis can be aligned coaxially with an axis of the ring gear. Accordingly, the aforementioned drive device for generating the rotational movement of the tool holder about its rotational axis can comprise the orbital body and a planetary gear. A drive shaft for driving the orbital body for its rotation about its orbital body axis can also be part of the aforementioned drive device.

[0037] A drive shaft for driving the revolving body to rotate about its revolving body axis may, in addition to the revolving body, also belong to a drive device for generating a movement of the revolving body.

[0038] Furthermore, a radial advance of the tool holder—perpendicular to a longitudinal axis of the workpiece or a workpiece holder holding the workpiece—can be provided, allowing the tool to engage ever deeper into the workpiece during machining. The tool holder can be advanced radially until the desired profile depth is reached.

[0039] For example, the radial feed can be realized by moving the revolving body or in particular a revolving body axis of the revolving body towards the longitudinal axis, i.e. in this sense experiencing a radial feed.

[0040] For example, the revolving body can be mounted in a profiling head, in particular, it can be mounted in the profiling head so that it can rotate about its revolving body axis, and the profiling head can be driven to move toward the longitudinal axis. Accordingly, the revolving body, while rotating about its revolving body axis, can be moved toward the longitudinal axis by means of a drive for radial infeed. And the revolving body axis can be moved accordingly toward the longitudinal axis.

[0041] As a result, the described complex movement of the tool holder (and the tool) can have an additional component, namely the described movement extending radially to the longitudinal axis (radial feed movement). The rotational axis of the tool holder can accordingly perform a movement resulting from a circular movement superimposed on a linear movement of the circle center, in particular, wherein the linear movement takes place in a plane defined by the circular movement.

[0042] Furthermore, a rotational movement of the workpiece or the workpiece holder about the longitudinal axis can be provided, for example generated by means of a corresponding drive device, for example by means of a torque motor, so that the workpiece can be machined by the tool at various positions distributed over the circumference of the workpiece. In this way, different profile gaps of the profiling to be created can be created by means of the tool. As explained further below, several tools can be provided so that not necessarily a single tool (or each of the tools) contributes to the formation of all profile gaps of the profiling. Nevertheless, it can be provided that the tool engages with the workpiece at every position along the circumference of the workpiece at which a profile gap of the profiling is to be created, and thus contributes to the formation of all profile gaps of the profiling.

[0043] Said rotational movement may have a varying rotational speed, in particular a rotational speed that varies periodically at least in sections. Said rotational movement may, for example, be an intermittent rotation.

[0044] The rotational speed of the workpiece or workpiece holder's rotational movement can be arranged to comprise successive phases of relatively higher rotational speed and relatively lower rotational speed. Machining of the workpiece by the tool can, in particular, take place during phases of relatively lower rotational speed. The slower the workpiece rotates during the tool's engagement, or the longer the workpiece rotates slowly or remains stationary during the phases of relatively lower rotational speed, the better the resulting profile can be achieved with high precision.

[0045] For example, it may be provided that the tool machines the workpiece during phases of the rotational movement in which the workpiece is stationary. For example, it may be provided that the tool machines the workpiece during phases of rotational standstill during intermittent rotation of the workpiece (rotational standstill has a rotational speed of zero).

[0046] On the other hand, it is also possible to provide for the rotational movement to have a constant rotational speed. This can result in increased productivity.

[0047] Synchronization of the rotational movement of the workpiece holder with the rotating movement of the tool holder can be provided. This ensures that the workpiece is always machined at the same positions along the circumference of the workpiece.

[0048] For example, a synchronization device, which is also referred to below as a first synchronization device, can be an electronic synchronization device.

[0049] In the above-described embodiment with planetary gear and recirculating body, the first synchronization device can, for example, synchronize the drive for the rotation of the workpiece or workpiece holder with the drive shaft for driving the recirculating body for its rotation about its recirculating body axis.

[0050] The method can therefore, in particular, be a method for producing a profiled body provided with a profile by cold forming a workpiece, wherein the workpiece can have a longitudinal axis and, in a processing area, an outer surface into which the profile is to be introduced. The outer surface can extend along the longitudinal axis. In particular, the outer surface can be concentric with the longitudinal axis, for example, conical or cylindrical. However, other shapes of the outer surface, such as polygonal shapes, for example, in prismatic processing areas, are also possible.

[0051] The workpiece rotates around its longitudinal axis. The workpiece, particularly the outer surface mentioned above, is machined by a tool in a number of successive forming operations, each of which involves the tool, or more precisely, an active area of ​​the tool, coming into contact with the machining area. The corresponding tool movement has already been described above.

[0052] The tool is held by a tool holder, and the tool holder is mounted in a revolving body for rotation about a rotational axis of the tool holder and is driven to rotate about its rotational axis. The tool holder is driven by the revolving body for revolving motion; in particular, the tool holder is driven by the revolving body for movement along an orbital path.

[0053] The tool is mounted in the tool holder so that it can rotate about a tool axis, whereby the tool axis is not identical to the rotation axis of the tool holder.

[0054] In particular, the tool axis can be spaced from the rotational axis of the tool holder. The two axes can, for example, be aligned parallel to each other. In the general case, which also includes non-parallel axes, "spaced" means that the axes, mathematically understood as straight lines, do not intersect.

[0055] Comparing the method described here with that in the aforementioned WO 2005 / 075125 A1, it can be seen that, with approximately the same diameter of the rotating body, approximately the same amount of force is available for forming, so that with large diameters, strong forming operations are possible even in solid material and for large gear modules. However, in the method described here, a length of a path (parallel to the axis of the workpiece holder or parallel to a profiling direction) in which the tool is close to the workpiece, for example, a length of a path along which the tool (more precisely: the effective area of ​​the tool) is in contact with the workpiece during an engagement, can be shorter than is the case in the aforementioned WO 2005 / 075125 A1.By superimposing the orbital motion with the rotary motion of the tool holder when the tool is non-coaxially mounted in the tool holder, the tool movement near the workpiece can be described as a movement along a hypocycloid, for example, an ellipse. This, in turn, near the engagement point, can be approximately described by a circular motion, whereby the diameter of this circular motion can be significantly smaller than the diameter of the orbital motion. This makes it possible to create profiles closer to an outwardly projecting shoulder of the workpiece to be profiled than is the case with the same orbital motion according to the method of WO 2005 / 075125 A1.

[0056] However, the process according to the aforementioned WO 2005 / 075125 A1 can also produce profiles similarly close to an outwardly protruding shoulder of the workpiece to be profiled. However, this only works if the orbital diameter is selected to be correspondingly small, for example, similar to the diameter of the circular movement just mentioned. However, this results in the forces available for forming the workpiece being significantly smaller, making it impossible to manufacture large gear modules from solid material.

[0057] On the other hand, if one compares the method described here with the method from the aforementioned WO 2020 / 099536 (using a sectorial tool), one finds that virtually any desired profile length can be produced with very good quality that remains consistent throughout the entire profile. In the method according to WO 2020 / 099536, however, this is only the case for profile lengths that correspond at most to the length of the effective range of the sectorial tool. This is because the material behavior, in particular the flow behavior, of the workpiece material is generally not constant along the profile, so that tight profiling tolerances can hardly be maintained for long profiles. For example, material of a tubular workpiece can be deformed and flow much more easily at one end of the workpiece than in the middle of the workpiece. Thus, the applicability of the method with a sectorial tool according to WO 2020 / 099536 is limited to relatively short profiles.

[0058] In particular, the tool can be freely rotatable around the tool axis. This means that the tool can be set in rotation around the tool axis by engaging the workpiece.

[0059] The tool can have an effective range that is rotationally symmetrical with respect to the tool axis. This allows the result of an intervention to be independent of the rotational orientation of the tool with respect to the tool axis during the intervention.

[0060] The tool can, for example, be designed as a rolling roller.

[0061] Furthermore, it may be provided that the rotational movement of the workpiece is synchronized with the rotating movement of the tool holder; and that the rotational movement of the tool holder is synchronized with the rotating movement of the tool holder.

[0062] In particular, it can be provided that the rotational movement of the workpiece is synchronized with the circumferential movement of the tool holder such that several of the forming operations take place at different positions distributed over the circumference of the workpiece. When an external profile is created, these positions can be positions at which profile gaps for the profiling are to be created. If the method creates an internal profiling of the workpiece, the positions can be positions that lie between adjacent profile gaps for the internal profiling to be created.

[0063] And in particular, it can also be provided that the rotary movement of the tool holder is synchronized with the rotating movement of the tool holder in such a way that the tool passes through the same azimuthal orientations during each of the forming operations.

[0064] If the rotary movement of the tool holder is synchronized with the rotating movement of the tool holder in such a way that the azimuthal orientations that the tool passes through during the respective forming operation are identical in each of the forming operations, a profiling can be created, for example, which extends close to a profiling limitation structure, for example to a workpiece projection.

[0065] Furthermore, it can be provided that, for the progressive formation of the profiling in the workpiece, a relative movement of the workpiece relative to the rotating body takes place parallel to the longitudinal axis. In particular, the rotating body, as described above, can have a rotating body axis around which it rotates, and a relative movement of the workpiece relative to the rotating body axis takes place parallel to the longitudinal axis.

[0066] For example, the workpiece can be driven to move parallel to the longitudinal axis (axial feed).

[0067] An axial feed can be used to ensure that the tool interventions take place at different axial positions (relative to the longitudinal axis) during the process. For example, a workpiece holder holding the workpiece can be driven by a drive in a direction parallel to the longitudinal axis.

[0068] The method can also be regarded as a method for profiling a workpiece and / or as a method for creating a profiling in a workpiece.

[0069] The workpiece can be a hollow part, in particular a rotationally symmetrical, for example cylindrical hollow part.

[0070] The workpiece can be a solid part, in particular a rotationally symmetrical, for example cylindrical, solid part.

[0071] The workpiece can be a metal workpiece.

[0072] The machining area can be an area in which the profiling is to be introduced, i.e., an area to be profiled. The machining area can be an axially limited section of the workpiece, for example, the end piece of a tubular or rod-shaped workpiece.

[0073] The workpiece may have a second region adjacent to the machining region. This second region may have a profiling limitation structure adjacent to the machining region, for example, a workpiece projection that has a radial extent around the longitudinal axis, at least in one (azimuthal) angular range, that is greater than a radial extent of the outer surface in the machining region where it adjoins the workpiece projection. The profiling limitation structure may be a profiling obstacle, for example, a workpiece shoulder.

[0074] A profiling boundary structure can form an end or a boundary of the profiling.

[0075] The outer surface in the machining area can be rotationally symmetrical, for example, cylindrical or conical. However, the outer surface can also be designed differently, for example, polygonal.

[0076] The profiling can be external profiling. This can be created in a hollow part or in a solid part. For example, with hollow parts, it is also possible to create both external and internal profiling simultaneously, for example, if the workpiece is intended to sit on an externally profiled mandrel in its machining area. Furthermore, it is also possible to create internal gearing in a hollow part without simultaneously creating external gearing. In this case, it is also possible for the workpiece to sit on an externally profiled mandrel in its machining area.

[0077] The profiling can have a multitude of profile gaps (recesses in the workpiece in the machining area) distributed around the circumference, for example, evenly distributed around the circumference. However, the profile gaps can also be unevenly distributed around the circumference.

[0078] The rotating movement of the tool holder can be a continuous movement and can in particular take place at a constant speed.

[0079] The rotational movement of the tool holder can be a continuous movement and can in particular occur at a constant rotational speed.

[0080] In particular, these two speeds can have a temporally constant relationship to each other.

[0081] The orbiting movement can be a circular movement.

[0082] A trajectory (movement path) that describes the movement of the tool holder can result in particular from a superposition of the circumferential movement with a (radial) movement perpendicular to the longitudinal axis.

[0083] In some embodiments, the revolving body rotates around a revolving body axis. This can generate the revolving movement of the tool holder. The revolving movement of the tool holder can take place in a plane perpendicular to the revolving body axis.

[0084] The orbiting body axis and the rotation axis can be aligned parallel to each other.

[0085] A direction of rotation of the rotary movement of the tool holder (around the axis of rotation) can, for example, be opposite to a direction of rotation of the orbital movement (around the orbital body axis) (opposite direction of rotation).

[0086] The rotating movement of the tool holder can take place in a plane to which the longitudinal axis is aligned parallel, and / or a plane perpendicular to the tool axis is perpendicular to a plane perpendicular to the longitudinal axis. This can be provided, in particular, to create a profile running parallel to the longitudinal axis, for example, a spur gear, especially if the rotational movement of the workpiece or the workpiece holder is slowed down during engagement or an intermittent rotational movement is provided.

[0087] On the other hand, for example, if helical gearing is to be created or if the workpiece is still rotating during the engagement, such as with a constant rotational speed of the workpiece or workpiece holder, a different orientation can be provided. For example, it can then be provided that a plane perpendicular to the tool axis encloses a non-zero pivot angle with the longitudinal axis. This pivot angle can be selected, for example, depending on the helix angle of the profiling or the rotational speed of the workpiece or workpiece holder during the engagement.

[0088] The rotation of the revolving body can be a continuous movement and, in particular, have a constant rotational speed. And the rotary movement of the tool holder can be a continuous movement and, in particular, have a constant rotational speed. And these two rotational speeds can have a temporally constant relationship to each other. Synchronization of these two rotational speeds can be achieved, for example, by means of a planetary gear, as already described above.

[0089] The planetary gear can comprise a ring gear and a planetary gear rotating within the ring gear. The planetary gear can be part of the tool holder, and can perform the rotary motion together with the tool holder. The position of the planetary gear can be fixed relative to the position of the tool axis.

[0090] The ring gear can be fixed in a profiling head in which the circulating body is mounted, in particular rotatably mounted.

[0091] The profiling head can be a bearing housing for receiving or storing parts of the device. For example, the profiling head can the circulating body must be mounted, in particular rotatably mounted; a drive for the rotation of the circulating body must be mounted; and a ring gear must be fixed, if present.

[0092] Furthermore, the profiling head can be operatively connected to a drive, for example a linear drive, for radial feed.

[0093] Two profiling heads can also be provided, each with at least one tool, for example, with a first tool in a first profiling head and a second tool in a second profiling head. These can be arranged opposite each other with respect to the longitudinal axis, for example, mirror-imaged with respect to a plane containing the longitudinal axis. Both tools can be designed, for example, as rolling rollers.

[0094] The two profiling heads, in particular including the device parts provided in them such as the revolving body and ring gear, can be designed identically or manufactured according to the same specifications, the movements of the device parts being mirror-inverted with respect to a plane containing the longitudinal axis.

[0095] The respective orbital movements of the two tools mentioned may be different from one another, namely, in particular, they may be mirror images of one another with respect to a plane containing the longitudinal axis. The respective orbital movements of the two tools mentioned may take place in one and the same plane.

[0096] The rotating movement of the first tool (the first profiling head) can be synchronized with the rotating movement of the second tool (the second profiling head) in such a way that the forming operations of the two tools take place simultaneously.

[0097] Due to the (mirror-) symmetrical design, mechanical stress on the workpiece holder can be kept low because the respective forces directed towards the longitudinal axis essentially cancel each other out.

[0098] Multiple tools may also be provided for other reasons and at other locations, for example, within the same profiling head. These tools may, for example, be of similar design. The tools may, for example, be rolling rolls, in particular rolling rolls of similar design. If multiple tool holders are provided, they may also be of similar design.

[0099] On the one hand, a single tool holder can hold two or more tools, for example in such a way that their tool axes are evenly distributed azimuthally with respect to the rotation axis of the tool holder.

[0100] For example, these tools can alternately engage the workpiece during successive cycles to form it.

[0101] This can result in an increased service life of the individual tools.

[0102] On the other hand, two or more tool holders can be provided, each holding (at least) one tool. The orbital movements of these tool holders can, for example, describe the same orbital path; and they can be evenly distributed along the orbital path. For example, these tool holders can be evenly distributed azimuthally with respect to the orbiting body axis.

[0103] For example, one intervention in the workpiece can take place per rotational revolution of the revolving body per tool holder.

[0104] This allows for a multiplication of operations per unit time (with the same number of revolutions of the revolving body), thus allowing faster machining of the workpiece. During one rotation period of the revolving body, N forming operations can take place, where N indicates the number of tool holders, each with (at least) one tool.

[0105] If N indicates the number of tool holders with n tools each and two identical (or mirror-image) stamping heads are provided, the workpiece can be machined with 2·N·n tools.

[0106] The tools or at least their effective areas can, for example, be manufactured according to the same specifications.

[0107] The tool can be a rolling roller, as described.

[0108] In its effective range, the tool can have a shape which, in a section along a cutting plane, corresponds to the negative of the shape of a profile gap of the generating profile, wherein this cutting plane runs through the effective range and contains the tool axis. In the event that a plane perpendicular to the tool axis is aligned perpendicular to a plane perpendicular to the longitudinal axis, it can be provided that, in a section perpendicular to the longitudinal axis through the effective range during an intervention, the tool has a shape which corresponds to the negative of the shape of a profile gap of the generating profile.

[0109] This can be particularly useful if the profiling includes or is an external profiling. Optionally, an internal profiling can also be created simultaneously with the external profiling—or not.

[0110] The effective range can be rotationally symmetrical with respect to the tool axis.

[0111] The effective range can be defined as the area of ​​the tool in which the tool comes into (direct) contact with the workpiece. However, it can be provided that only a portion of the effective range comes into (direct) contact with the workpiece during each engagement. For a tool mounted so it can rotate freely around the tool axis, it is essentially random which portion of the effective range comes into (direct) contact with the workpiece during an engagement.

[0112] If the tool is held by the tool holder as described, the tool axis can rotate with the associated tool holder. And if a planetary gear is provided that is part of the tool holder, the relative position of the tool axis to the planetary gear can also be constant.

[0113] The tool can be part of a tool insert of the tool holder, which can be fixed to at least one other part of the tool holder.

[0114] The device can be a device for producing a profiled body by cold forming a workpiece. For this purpose, the device can comprise: a workpiece holder rotatable about its longitudinal axis for holding the workpiece; a drive device for generating a rotational movement of the workpiece holder about the longitudinal axis, in particular wherein the rotational movement is intermittent or has alternating periods of standstill and periods of rotational movement; a circulating body; a tool holder for holding a tool, in particular wherein the tool holder is rotatably mounted in the circulating body about an axis of rotation of the tool holder; a drive device for generating a rotational movement of the tool holder about its axis of rotation; and a drive device for generating a movement of the circulating body, by means of which the tool holder can be driven to perform a circulating movement, in particular along an orbit.

[0115] Furthermore, the device may comprise: a first synchronization device for synchronizing the rotational movement of the workpiece holder with the rotating movement of the tool holder; and a second synchronization device for synchronizing the rotational movement of the tool holder with the rotating movement of the tool holder.

[0116] The tool holder may have a pivot bearing that defines a tool axis different from the rotational axis of the tool holder, for receiving the tool; specifically, such that the tool is rotatable about the tool axis. In particular, the tool may be freely rotatable about the tool axis.

[0117] In some embodiments, the device has the tool mounted in the pivot bearing so that it can rotate about the tool axis.

[0118] In particular, it can be provided that the tool has an effective area which is rotationally symmetrical with respect to the tool axis; and / or is designed as a rolling roller.

[0119] The drive device for generating a rotational movement of the tool holder about its rotational axis can be at least partially identical to the second synchronization device. For example, the planetary gear mechanism already described can, on the one hand, be part of this drive device by converting the movement of the revolving body into the rotational movement of the tool holder, and, on the other hand, it can be part of the first synchronization device (or correspond to the first synchronization device) by coupling the rotational movement of the tool holder to the revolving movement of the tool holder.

[0120] The drive device for generating a movement of the revolving body can, for example, comprise a drive spindle. This can also be part of the drive device for generating a rotational movement of the tool holder about its rotational axis, e.g., mediated by the planetary gear.

[0121] The revolving body can be mounted in a profiling head, in particular, mounted for rotation. This can be driven by a drive toward the longitudinal axis for the radial feed movement. The drive can, for example, be a drive for a movement of the profiling head perpendicular to the longitudinal axis.

[0122] The device can include a drive device for generating a movement of the workpiece holder parallel to the longitudinal axis. This allows tool engagement, for example, to take place successively at positions increasingly farther from one end of the workpiece. A progressive formation of the profile parallel to the longitudinal axis can be enabled.

[0123] The first synchronization device and the second synchronization device may be one and the same synchronization device or may be completely or partially different from each other.

[0124] The first synchronization device can be configured to ensure that a rotational frequency of the rotating movement of the first tool holder is in a fixed (time-unchanged) relationship with a speed of the rotational movement of the workpiece.

[0125] The second synchronization device can be configured to ensure that a rotational frequency of the rotating movement of the first tool holder is in a fixed (time-unchanged) relationship with a speed of the rotary movement of the tool holder.

[0126] The device can be configured so that the cold forming of the workpiece can be performed through a plurality of successive forming operations. These operations can be performed by a single tool or by multiple tools.

[0127] And the first synchronization device can be configured to synchronize the rotational movement of the workpiece holder with the rotating movement of the tool holder in such a way that several of the forming interventions take place at different positions distributed over a circumference of the workpiece.

[0128] The device can be configured such that, in each of the forming operations, a tool comes into contact with the machining area. In particular, the device can be designed such that, in each of the forming operations, the effective area (more precisely: a section of the effective area) of a tool comes into contact with the machining area. The respective tool (more precisely: its effective area or section of the effective area) can exert a hammering action on the outer surface (in the machining area). During each of the operations, a tool can exert a cold-forming action on the machining area.

[0129] And the second synchronization device can be configured to synchronize the rotary movement of the tool holder with the rotating movement of the tool holder such that the tool axis passes through the same (small) range of azimuthal positions (relative to the rotary axis) in each of the forming interventions of the tool.

[0130] If a plurality of tools and one or more tool holders (each holding at least one of the tools) are provided, it can be provided that the second synchronization device is configured to synchronize the rotary movement of the at least one tool holder with the rotating movement of the respective tool holder in such a way that each of the tool axes passes through the same (small) range of azimuthal positions (relative to the rotary axis) in each of the forming interventions of the corresponding tool.

[0131] For example, if the profiling to be created has r profile gaps and the device has N tool holders whose orbital movement describes one and the same orbit, the first synchronization device can be set up such that an N-th of a period of the orbital movement is equal to an integer multiple of an r-th of the period of the rotational movement of the workpiece. As a result, the interventions take place precisely at the positions along the circumference of the workpiece where profile gaps are to be created. In particular, the first synchronization device can be set up such that an N-th of a period of the orbital movement is equal to an r-th of the period of the rotational movement of the workpiece. As a result, the interventions take place at adjacent profile gap positions.

[0132] The invention includes devices with features that correspond to the features of described methods and, conversely, also methods with features that correspond to the features of described devices.

[0133] Further embodiments and advantages emerge from the dependent claims and the figures.

[0134] The subject matter of the invention is explained in more detail below using exemplary embodiments and the accompanying drawings. They show schematically: Fig. 1 shows a device for carrying out the method for cold-forming profiling of a workpiece; Figs. 2A-2D show successive phases of the method; Fig. 3 shows a tool holder with tool, in a section through its rotational axis and the tool axis; Fig. 4 shows a detail of a planetary gear with a planetary gear according to Fig. 3 ; Fig. 5 a detail of a device with two profiling heads, with symbolized radial infeed and axial feed; Fig. 6A an orbit of a tool holder; Fig. 6B a radial infeed movement, symbolic; Fig. 6C a trajectory of a tool holder, as a superposition of orbital movement and radial infeed; Fig. 7 a detail of a device with two profiling heads, each having three tool holders with two tools each; Fig. 8 a profile body with an outwardly projecting shoulder; Fig. 9 a detail of a workpiece on an externally profiled mandrel, in a section perpendicular to the longitudinal axis; Fig. 10 a workpiece with a conical machining area, in a section containing the longitudinal axis; Fig. 11 a workpiece with a polygonal outer surface, in a section perpendicular to the longitudinal axis; Fig. 12 a workpiece ora profile body with two axially spaced, radially outwardly directed profiling limiting structures, between which a profiling was created; Fig. 13 a workpiece or a profile body with two axially spaced, radially inwardly or outwardly directed profiling limiting structures, between which a profiling was created; Fig. 14 a workpiece or a profile body without profiling limiting structures; Fig. 15 a workpiece with a non-rotationally symmetrical profiling limiting structure, in a section perpendicular to the longitudinal axis; Fig. 16 a workpiece or a profile body with azimuthally unevenly distributed profile gaps, in a section perpendicular to the longitudinal axis; Fig. 17 a schematic illustration of the situation with a pivoted tool axis.

[0135] Parts not essential to understanding the invention are partly omitted. The described embodiments are exemplary of the subject matter of the invention or serve to explain it and are not limiting.

[0136] Fig. 1 shows a device 100 for carrying out the method for cold forming profiling of a workpiece 1. The workpiece 1 is held in a workpiece holder 10, which is in Fig. 1 is symbolically represented and has a longitudinal axis Z, which is also a longitudinal axis of the workpiece 1.

[0137] In the example shown, the workpiece 1 has a machining area 11 which is rotationally symmetrical with respect to the longitudinal axis Z and has an outer surface 11a, which is, for example, cylindrical in shape and in which a profiling is to be introduced, and which is adjoined by a second area 12 in which the workpiece 1 has a larger diameter than in the machining area 11. As a result, a profiling limitation structure designed as a workpiece shoulder 13 is formed between the areas 11 and 12.

[0138] Next is a Fig. 1 symbolically represented circulating body 8 is provided, which executes a movement R8', namely by rotating in the example shown by a Fig. 1 not shown, rotates and thus performs the rotation R8'. A tool holder 5 is mounted in the revolving body 8, which, due to the movement R8' of the revolving body 8, performs a revolving movement R8 along an orbit U.

[0139] The tool holder 5 has a rotational axis W around which it performs a rotational movement R5. This rotational movement R5 can, for example, be generated directly by a drive (rotational drive) or can be derived from the movement R8' of the revolving body 8, for example, mechanically, for example by means of a planetary gear, as will be described in more detail below.

[0140] The tool holder 5 holds at least one tool 2, which has an active area 21 in which it comes into cold-forming contact with the workpiece 1, specifically by performing a movement during engagement with the workpiece 1, which movement will be described in more detail below. The tool 2 is mounted in the tool holder 5 so as to be rotatable about the tool axis Q, in particular so as to be freely rotatable. The tool axis Q is not identical to the rotational axis W of the tool holder 5. For example, it can be aligned parallel to it and spaced apart from it.

[0141] The tool 2 can have a rotationally symmetrical effective range (with respect to the tool axis Q).

[0142] The tool 2 can, for example, be designed as a rolling roller.

[0143] By means of the tool 2, profile gaps are created in the workpiece 1, whereby the tool 2 carries out a plurality of interventions per profile gap.

[0144] In order for the tool 2 to engage in the workpiece 1 at various positions distributed over the circumference of the workpiece 1, the workpiece 1 can be driven by means of the workpiece holder 10 about the longitudinal axis Z to perform a rotational movement R1, in particular wherein the rotational movement R1 can be an intermittent rotation, so that the tool engagement can take place in each phase of the rotational standstill of the workpiece 1.

[0145] Furthermore, a drive for an axial feed of the workpiece 1 parallel to the longitudinal axis Z can be provided. This can cause the profiling to progress along the longitudinal axis Z.

[0146] In Fig. 1 Active connections for the purpose of drive are shown by dashed lines and active connections for the purpose of synchronization (which can be implemented mechanically and / or electronically) are shown by thick dotted lines.

[0147] A drive device A1 is provided for generating a rotational movement R1 of the workpiece holder 10, for example a torque motor or another rotational drive, and a drive device A8 for generating the movement R8' of the circulating body 8. The drive device A8 can, for example, have a drive shaft.

[0148] And a drive device A5 is also provided for generating the rotational movement R5 of the tool holder 5 about its rotational axis W, as already stated above.

[0149] The rotational axis W is aligned parallel to the revolving body axis. The revolving movement R8 of the tool holder occurs in a plane to which these axes are perpendicular. In the example shown, the longitudinal axis is aligned parallel to this plane.

[0150] The tool axis Q can be aligned parallel to the rotation axis W.

[0151] In order for tool interventions to take place where profile gaps are to be created, the workpiece rotation R1 and the circulating movement R8 are synchronized with each other by means of a first synchronization device S1, for example by synchronizing the workpiece rotation R1 and the movement R8' of the circulating body 8 with each other by means of the first synchronization device S1.

[0152] For example, synchronization can consist in the two movements (R1 and R8 or R8') having a temporally constant ratio of their revolution times. For example, if only one tool 2 is provided and successive engagements of the tool 2 in the workpiece 1 are to occur in adjacent profile gaps, T8 / T1 = z can be selected, with a revolution time (period) T8 of the revolution movement R8 of the tool holder 5 and a revolution time (period) T1 of the workpiece, where z is the number of profile gaps to be created.

[0153] This synchronization can be achieved, for example, using an electronic synchronization device S1. However, other synchronization devices, such as mechanical ones, are also conceivable.

[0154] Furthermore, a second synchronization device S5 is provided, by means of which the rotary movement R5 of the tool holder 5 and the rotating movement R8 of the tool holder 5 are synchronized with each other. This can be achieved, for example, by means of an electronic synchronization device, which can then also be identical to the first synchronization device S1. In the example shown, this synchronization is realized mechanically, namely by means of the planetary gear mechanism already mentioned.

[0155] In this respect, the drive device A5 can be at least partially identical to the second synchronization device S5, namely in that the planetary gear on the one hand generates the rotary movement R5 and on the other hand effects the synchronization between the rotary movement R5 and the orbital movement R8.

[0156] The synchronization achieved by means of the second synchronization device S5 can ensure that the tool axis Q assumes the same azimuthal orientation (relative to the rotational axis W of the tool holder 5) during each engagement with the workpiece 1. This can be advantageous, for example, when the workpiece 1, as in Fig. 1 shown has an outwardly projecting workpiece shoulder 13 and the profiling is to be carried out close to this. This is shown in Figs. 2A bis 2D explained.

[0157] Figs. 2A-2D illustrate successive phases of the process. Most of the reference symbols have already been explained above; φ denotes an azimuthal position of the tool axis relative to the rotation axis W, or, more precisely, the corresponding azimuthal angle (measured counterclockwise). Reference axes for the azimuthal orientation can be, for example, as in Figs. 2A-2D (and also in Fig. 4 , see below): an axis perpendicular to the axis of rotation W (in Figs. 2A-2D shown in dashed lines), which runs through the center of the effective area 21 and through the axis of rotation W; and an axis aligned perpendicular to the axis of rotation W (in Figs. 2A-2D shown dotted), which runs through the center of the effective area 21 and through the orbiting body axis.

[0158] Fig. 2A illustrates the situation shortly before the start of an operation, where the tool 2 shortly afterwards comes into contact with the workpiece 1. The azimuthal angle φ in the illustrated example is approximately 317°, corresponding to -43°.

[0159] Fig. 2B illustrates the situation approximately in the middle of the intervention. The azimuthal angle φ in the illustrated example is a few degrees.

[0160] Fig. 2C illustrates the situation shortly after the end of an operation. Tool 2 is no longer in contact with workpiece 1. The azimuthal angle φ is approximately 40° in the illustrated example.

[0161] Fig. 2D illustrates the situation even later after the end of an operation. Shortly thereafter, tool 2 moves over the workpiece shoulder 13. The azimuthal angle φ in the illustrated example is a good 70°.

[0162] By means of the second synchronization device S5, it can be ensured, for example, that during each revolution the tool 2 only comes into contact with the workpiece 1 in a small azimuthal angle range, which here is, for example, close to 0°, and thus forms it by hammering.

[0163] By superimposing the orbital movement of the tool holder with the rotary movement of the tool holder about the axis of rotation, it can be ensured that the tool 2 - due to the non-identity of the tool axis and the axis of rotation - is in contact with the workpiece 1 for only a very short time and along only a very short section (measured, for example, parallel to the longitudinal axis Z).

[0164] This prevents the tool 2 from coming into (forming) contact with the workpiece shoulder 13 - and yet the profile can still be formed close to the workpiece shoulder 13.

[0165] As can be seen from Fig. 2A As can be easily seen, workpiece 1 could have a further workpiece projection at the end shown on the right, instead of ending there (in Fig. 2A indicated by dotted lines). In such a case, it is possible, using the described method, to create the profiling between the two workpiece projections in such a way that it extends close to the respective workpiece projection.

[0166] Fig. 3 shows a tool holder 5 with tool 2, in a section through its rotational axis W and through the tool axis Q. It has (optionally) two planetary gears 45, whose axes are coaxial with the rotational axis W, and two bearing areas 2L for the rotatable bearing in the recirculating body 8 (see Fig. 1 ). The tool holder 5 can be formed in one piece or, as shown, in several parts.

[0167] The tool holder 5 can, for example, have a tool insert 2e (in Fig. 3 hatched for better visibility), in which the tool 2 is mounted rotatably about the tool axis Q. For example, as in Fig. 3 As shown, a rolling roller as tool 2 can be mounted there so as to be freely rotatable about the tool axis Q. The tool insert 2e can have a pivot bearing for this purpose (not separately shown in the figure). The tool insert 2e can be fixedly connected to at least one other part of the tool holder 5, for example, by being screwed thereto.

[0168] The tool axis Q can be fixedly positioned relative to the planetary gears 45 in the tool holder 5.

[0169] Fig. 4 illustrates in a view of a section perpendicular to the axis of rotation W a detail of a planetary gear 40 of the device, for example comprising planetary gears 45, as they are in the tool holder 5 according to Fig. 3 are integrated, of which Fig. 4 but only one is visible.

[0170] The planetary gear 40 has a ring gear 41 with an axis 42 and can also have a second, Fig. 4 not shown ring gear in which the second planet gear of the tool holder 5 runs.

[0171] The axis 46 of the planetary gear 45 is coaxial with the rotation axis W. And the orbiting body axis V (corresponding to the axis of the orbiting movement of the tool holder) is coaxial with the axis 42 of the ring gear 41.

[0172] By appropriately dimensioning the planetary gear 40, it can be ensured, for example, that the tool axes Q are at a specific position along the orbit U (see Fig. 1 ) of the tool holder 5, for example where the engagement in the workpiece 1 is to end, or where the engagement in the workpiece 1 is to begin, has the same azimuthal position (relative to the axis of rotation) during each revolution.

[0173] Instead of a planetary gear with two ring gears and two planet gears, the planetary gear can also be realized with no more than one ring gear and no more than one planet gear.

[0174] The mechanical requirements on the workpiece holder 10 can be greatly reduced if two tool interventions take place for each tool intervention, namely at opposite points of the workpiece 1 with respect to the longitudinal axis, and in particular also axially (with respect to the longitudinal axis Z) at the same position.

[0175] Fig. 5 illustrates a detail of a device 100 with two profiling heads 3a, 3b, with a radial infeed and an axial feed also symbolized. The recirculating bodies (including at least one tool holder each) and, if provided, the planetary gears can be mounted in the profiling heads 3a, 3b.

[0176] The profiling heads 3a, 3b or the parts mounted in them can be essentially of the same type, but mirror-image in terms of movements.

[0177] The Fig. 5 The workpiece 1 symbolically shown (dashed) can thus be machined in a mirror image by two tools opposite each other with respect to the longitudinal axis Z.

[0178] The movements of the two revolving bodies can be synchronized with each other or result from one and the same movement, for example, from the same rotary drive. One or more ring gears can be fixed in each of the profiling heads.

[0179] During machining, it can be advantageous if the workpiece can be moved axially, i.e., in a direction parallel to the longitudinal axis Z, to enable progressive profiling along the longitudinal axis Z through a plurality of successive tool engagements in the workpiece. This naturally also applies if only a single profiling head is provided, or if the tool engagements occur only from one side, or if no more than one tool is used at a time.

[0180] Such an axial movement is in Fig. 5 symbolized by the large black filled arrow.

[0181] An AZ drive for axial feed can be provided for this purpose.

[0182] During machining, it can be advantageous if the tools can be advanced radially, i.e., in a direction perpendicular to the longitudinal axis Z, since the profile gaps that are being created become increasingly deeper with the increasing number of cuts. This also applies if only a single profiling head is provided, or if tool engagement occurs from only one side, or if no more than one tool is used at a time.

[0183] Such a radial feed movement is in Fig. 5 symbolized by the open arrows labeled L2. It can occur along an axis perpendicular to the longitudinal axis and parallel to a plane described by the rotating motion of the tool holder.

[0184] A drive A2 can be provided for radial feed.

[0185] Due to the radial infeed, the trajectory or movement path of the tool holder results from a superposition of the rotating movement U with the (linear) radial infeed movement, as shown in Figs. 6A-6C is illustrated schematically.

[0186] Fig. 6A symbolizes an orbit U of a tool holder.

[0187] Fig. 6B symbolizes a radial infeed movement L2.

[0188] Fig. 6C symbolizes a trajectory T of a tool holder, which results from the superposition of the circular movement U and the radial infeed L2. In reality, the distances between the approximately circular trajectory components are much smaller than in Fig. 6C shown for the sake of clarity.

[0189] Fig. 7 illustrates a detail of a device 100 with two profiling heads, each having three tool holders 5a1, 5a2, 5a3 or 5b1, 5b2, 5b3 with two tools 2a1, 2a1' or 2a2, 2a2' etc.

[0190] By providing several tool holders 5a1, 5a2,... (if necessary per profiling head), several interventions can take place per revolution of a circulating body, which can enable faster machining and thus the creation of the profiling within a shorter time.

[0191] By providing several tools per tool holder, their service life can be increased and thus longer uninterrupted profiling is possible. For example, the second synchronization device S5 (see Fig. 1 ) be set up so that with n tools per tool holder, the tool axis of the respective tool after one revolution of the revolving body 8 is at a certain position along the orbit U (see Fig. 1 ) of the tool holder 5 (for example, where the engagement with the workpiece 1 is to be terminated) has an azimuthal orientation that deviates by 360° / n from the azimuthal position at the beginning of the revolution. The deviation can also be a multiple of 360° / n, provided that this multiple is different from 360° and from a multiple of 360°.

[0192] Further on, Fig. 7 illustrates that by means of the method described in this text, profilings can also be created between two profiling limiting structures, for example between the two workpiece shoulders 13, 13', whereby the profilings can each reach close to the profiling limiting structures.

[0193] Fig. 8 shows a section perpendicular to the longitudinal axis Z of a profile body 1p having a profile P that can be produced by means of the described method or by means of the described device. The profile has a plurality of profile gaps pl. Each of these profile gaps pl is created by the sequential execution of a plurality of interventions by one or more tools 2, each of which has an effective area 21, which in the section according to Fig. 8 has a shape which essentially corresponds to the shape of a profile gap pl to be created.

[0194] The profile body 1p is a hollow part that sits on an externally profiled mandrel 6 and has an outwardly projecting shoulder 13. By using a profiled mandrel 6, the process can produce not only an external profile but also an internal profile at the same time.

[0195] For solid parts or hollow parts sitting on unprofiled mandrels, an external profiling can be created without simultaneously creating an internal profiling.

[0196] Furthermore, it is possible to create an internal toothing in a hollow part without creating an external profile in the hollow part. Fig. 9 illustrates this.

[0197] Fig. 9 shows, in a section perpendicular to the longitudinal axis, a detail of a workpiece 1, which sits on an externally profiled mandrel 6 and is about to be machined by means of a tool 2 in the manner described. During the machining, material of the workpiece 1 is then formed into profile gaps 6p. The tool 2 has a flat effective area.

[0198] Fig. 10 shows, in a section containing the longitudinal axis Z, by way of example, that an outer surface of a machining area 11 of a workpiece 1 does not have to be cylindrical, but can, for example, be conical, as shown.

[0199] Fig. 11 shows in a section perpendicular to the longitudinal axis Z, using an example, that an outer surface 11a of a machining area 11 of a workpiece 1 does not necessarily have to be rotationally symmetrical, but can, for example, be polygonal, as shown. Shown in Fig. 11 In this case, the outer surface 11a has six partial surfaces; however, it can be provided that the outer surface 11a has many more partial surfaces. In the associated machining area, the workpiece 1 can, for example, be prismatic.

[0200] Fig. 12 shows an example of a workpiece 1 or a profile body 1p with two axially spaced profiling delimitation structures 13, 13' that extend radially outward. The profiling P with its profile gaps pl, which is produced using the described method, extends close to these.

[0201] Profiling limit structures may also be directed radially inward relative to the adjacent portion of the machining area. Fig. 13 shows an example in which the profiling limiting structures 13 at one end of the machining area 11 are directed radially inwards and the profiling limiting structures 13' at the other end of the machining area 11 are directed radially outwards.

[0202] Fig. 14 Using an example, it illustrates that a machining area 11 does not necessarily have to be delimited on one or two sides by profiling delimitation structures. A profile body is shown in which both ends of the machining area 11 are not adjacent to profiling delimitation structures.

[0203] Fig. 15 illustrates by way of example that a profiling limitation structure 13 of a workpiece 1 is not necessarily rotationally symmetrical. In the illustrated example, a plurality of radially outwardly projecting workpiece projections are provided, which are located at different azimuthal positions.

[0204] Fig. 16 illustrates, in a section perpendicular to the longitudinal axis L, a workpiece 1 or a profile body 1p having a profile whose profile gaps 1p are azimuthally unevenly distributed. Although profile gaps evenly distributed over the circumference are preferred for many applications, there are applications for which an azimuthally irregular arrangement of the profile gaps pl is advantageous.

[0205] Of course, a single workpiece can have two or more different machining areas, which can, for example, be axially spaced from one another, and which can each be provided with a profile in the manner described in this text.

[0206] In the Figuren 1 , 5 , 7In the examples shown, a plane perpendicular to the tool axis Q contains the longitudinal axis Z. However, this is only an option. As already mentioned above, this option can be particularly useful, for example, when a spur gear is to be produced and the workpiece is stationary or rotating only slowly during the cutting operation.

[0207] However, it can also be provided that a plane perpendicular to the tool axis includes a swivel angle δ (not equal to zero degrees) with the longitudinal axis, as in Fig. 17 This can be useful for producing inclined profiles, such as helical gears, or even when the workpiece 1 rotates during tool engagement, such as in the case of a rotational movement of the workpiece 1 or workpiece holder with a constant rotational speed. In particular, as in Fig. 17 shown, the (pivoted) tool axis Q' is pivoted relative to a vertically aligned tool axis Q in a direction that is parallel to the longitudinal axis Z; in other words: it is pivoted in such a way that the non-pivoted tool axis Q lies together with the pivoted tool axis Q' in a plane that is parallel to the longitudinal axis Z. The said plane is in Fig. 17 the drawing plane. A plane perpendicular to the pivoted tool axis Q' is Fig. 17 shown in dash-dotted lines and includes the swivel angle δ with the longitudinal axis, just as the swiveled tool axis Q includes the swivel angle δ with the non-swiveled tool axis Q. The size of the swivel angle δ can be selected, for example, depending on the helix angle of the profiling or the rotation speed of the workpiece or workpiece holder during the intervention.

[0208] For example, the profiling head can be swiveled so that the tool axis Q, the rotation axis W (of the tool holder) and the revolving body axis V are swiveled simultaneously.

[0209] If the tool axis Q, the rotation axis W, and the revolving body axis V are parallel to each other, they can all be pivoted by the same pivot angle δ, for example. Then, due to the mutual parallelisms, the plane perpendicular to the tool axis Q is also perpendicular to the rotation axis W and the revolving body axis V.

[0210] As explained above, the process described here can make it possible to produce profiles that require large forces, while still allowing profile formation close to profile limiting structures (such as workpiece shoulders).

Claims

1. A method for manufacturing a profile body (1p) which is provided with a profiling (P) by way of cold forming a workpiece (1) which comprises a longitudinal axis (Z) and, in a machining region (11), an outer surface (11a), into which the profiling (P) is to be incorporated, wherein the workpiece (1) carries out a rotation movement (R1) about the longitudinal axis (Z) and is machined by a first tool (2) in a multitude of successively executed reshaping engagements in which the first tool (2) comes into contact with the machining region (11), wherein the first tool (2) is held by a first tool holder (5; 5a1), and wherein the first tool holder (5; 5a1,...) - is mounted in an orbiting body (8) to be rotatable about a rotation axis (W) of the first tool holder (5; 5a1,...) and is driven into a rotation movement (R5) about the rotation axis (W), wherein the term azimuthal which is used hereinafter is defined by the rotation axis (W); and - is driven into an orbiting movement (R8) by the orbiting body (8); and wherein - the rotation movement (R1) of the workpiece (1) is synchronised with the orbiting movement (R8) of the first tool holder (5; 5a1, ...); and - the rotation movement (R5) of the first tool holder (5; 5a1,...) is synchronised with the orbiting movement (R8) of the first tool holder (5; 5a1, ...); characterized in that the first tool (2) is mounted, in particular freely rotatably mounted, in the first tool holder (5; 5a1, ...) to be rotatable about a first tool axis (Q) which is different from the rotation axis (W), in particular wherein the first tool axis (Q) is distanced to the rotation axis (W).

2. Method according to claim 1, wherein - the rotation movement (R1) of the workpiece (1) is synchronised with the orbiting movement (R8) of the first tool holder (5; 5a1,...) such that at each of a number of different positions distributed over a circumference of the workpiece (1), several of the reshaping engagements take place; and - the rotation movement (R5) of the first tool holder (5; 5a1,...) is synchronised with the orbiting movement (R8) of the first tool holder (5; 5a1,...) such that the first tool (2) runs, for each of the reshaping engagements, through the same azimuthal orientations (ϕ).

3. Method according to claim 1 or claim 2, wherein the orbiting body (8) carries out a rotation (R8') about an orbiting body axis (V), and wherein the orbiting body axis (V) and the rotation axis (W) are aligned parallel to one another.

4. Method according to one of the claims 1 to 3, wherein the first tool (2) comprises an active region (21) which is rotationally symmetric with respect to the tool axis (Q), in particular wherein the first tool (2) is embodied as a roller.

5. Method according to one of the claims 1 to 4, wherein the rotation movement (R5) of the tool holder (5; 5a1,...) is synchronised with the orbiting movement (R8) of the first tool holder (5; 5a1,...) by way of a planetary gear (40).

6. Method according to claim 5, wherein the planetary gear (40) comprises a ring gear (41) and a planet wheel (45) which runs in the ring gear (41), wherein the planet wheel (45) is part of the first tool holder (5; 5a1,...) and together with this executes the rotation movement (R5).

7. Method according to one of the claims 1 to 6, wherein the workpiece is simultaneously machined by a second tool (2b) in a multitude of successively executed reshaping engagements in which the second tool (2b) comes into contact with the workpiece (1), in particular wherein each of the successively executed reshaping engagements of the second tool (2b) takes place at a position of the workpiece (1) which lies opposite that position of the workpiece (1) with respect to the longitudinal axis (Z) at which simultaneously a reshaping engagement of the first tool (2a) takes place; in particular wherein the first tool (2a) and the second tool (2b) is embodied as a roller.

8. Method according to one of the claims 1 to 7, wherein the workpiece is additionally machined by a further tool (2a2, 2a1') in a multitude of successively executed reshaping engagements, in which the further tool (2a2, 2a1) comes into contact with the workpiece (1), in particular wherein a tool holder (5; 5a2,...) which holds the further tool (2a1') carries out the same orbiting movement (R8) as the already mentioned tool holder (5; 5a1,...), and wherein this further tool holder (5; 5a2) is identical to the already mentioned tool holder (5; 5a1,...) or is different to this; in particular wherein the first tool (2a) and the further tool (2a2, 2a1') are embodied as rollers.

9. Method according to claim 8, wherein the further tool (2a1') is held by the same tool holder (5a1) as the first tool (2; 2a1), in particular wherein the further tool (2a1; 2a1') is mounted in the tool holder (5a1) to be rotatable about a further tool axis which is different from the rotation axis (W) and from the first tool axis (Q), in particular wherein the further tool axis is azimuthally distanced to the first tool axis (Q), and in particular wherein the first (Q) and the further tool axis and the rotation axis (W) are aligned perpendicularly to a common plane.

10. Method according to claim 8, wherein a second tool holder (5a2) is provided, said second tool holder being different from the first tool holder (5a1), and by way of the second tool holder the further tool (2a2) is rotatably held about a further tool axis, wherein the orbiting movements of the first and of the second tool holder describe the same orbiting path (U), in particular wherein the further tool (2a2) is mounted in the second tool holder (5a2) to be rotatable about a further tool axis which is different from a rotation axis of the second tool holder, and in particular wherein the first (Q) and the further tool axis and the rotation axis (W) are aligned perpendicularly to a common plane.

11. A device (100) for manufacturing a profile body (1p) which is provided with a profiling (P) by way of cold forming a workpiece (1), wherein the device (100) comprises: - a workpiece holder (10) which is rotatable about its longitudinal axis (Z), for holding the workpiece (1); - a drive device (A1) for producing a rotation movement (R1) of the workpiece holder (10) about the longitudinal axis (Z); - an orbiting body (8); - a first tool holder (5; 5a1) for holding a first tool (2a; 2a1), wherein the tool holder (5; 5a1) is mounted in the orbiting body (8) to be rotatable about a rotation axis (W) of the tool holder (5; 5a1); - a drive device (A5) for producing a rotation movement (R5) of the first tool holder (5; 5a1) about its rotation axis (W); - a drive device (A8) for producing a movement of the orbiting body (8), by way of which the first tool holder (5; 5a1) is drivable into an orbiting movement (R8); - a first synchronisation device (S1) for synchronising the rotation movement (R5) of the workpiece holder (10) with the orbiting movement (R8) of the first tool holder (5; 5a1); - a second synchronisation device (S5) for synchronising the rotation movement (R5) of the first tool holder (5; 5a1) with the orbiting movement (R8) of the first tool holder (5; 5a1); characterized in that the first tool holder (5; 5a1) comprises a first rotation bearing for receiving the first tool (2; 2a1), said first rotation bearing defining a first tool axis (Q) which is different from the rotation axis (W) of the first tool holder (5; 5a1), so that the first tool (2; 2a1) is rotatable, in particular freely rotatable, about the first tool axis (Q).

12. Device (100) according to claim 11, comprising the first tool (2; 2a1), mounted in the first rotation bearing to be rotatable about the first tool axis (Q), in particular wherein the first tool (2; 2a1) - comprises an active region (2) which is rotationally symmetric with respect to the first tool axis (Q); and / or - is embodied as a roller (2; 2a1).

13. Device (100) according to claim 11 or claim 12, wherein the device (100) comprises a drive device (AZ) for producing a movement of the workpiece holder (100) parallel to the longitudinal axis (Z).

14. Device (100) according to one of the claims 11 to 13, comprising a planetary gear (40) which is a constituent of the second synchronisation device (S5) and / or a constituent of the drive device (A5) for producing a rotation movement (R5) of the first tool holder (5; 5a1) about the rotation axis (W).

15. Device according to one of the claims 11 to 14, wherein the orbiting body (8) is mounted in a profiling head (3), and wherein the device (100) comprises a drive (A2) for a movement of the profiling head (3) towards the longitudinal axis (Z).