Axial Forming Control for Precise Shaft Toothing Profiles
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Solution Overview
Problem
Existing axial forming processes lack the ability to dynamically adjust the oscillating relative movement between the shaping tool and the workpiece to achieve precise alignment with the target geometry, particularly in the automotive sector for producing shafts with complex profiles like toothing.
Innovation Solution
A programmable numerical drive controller is used to vary the oscillating relative movement between the shaping tool and the workpiece based on empirical adjustments, considering factors like workpiece rigidity, material properties, and lubrication, to ensure the actual geometry aligns with the target geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a non-uniform oscillating relative movement is used in axial forming, then the workpiece can be formed over a predetermined length, but the actual geometry deviates from the target geometry due to workpiece rigidity and material properties
Solution Approach 1:
The patent applies dynamics by making the oscillating relative movement parameters variable during the forming process. The forming drive is designed to dynamically adjust the oscillation amplitude, frequency, and stroke length based on real-time feedback about the workpiece geometry, allowing the system to adapt to workpiece rigidity variations and material properties throughout the forming operation.
Solution Approach 2:
The patent implements parameter changes by modifying the oscillating movement parameters (amplitude, frequency, stroke length) during the forming process. The control system varies these parameters based on measured workpiece geometry and material response, enabling precise control over the forming outcome and eliminating geometry deviations caused by workpiece rigidity and material properties.
2Manufacturing precision
If fixed oscillating movement parameters are used, then the forming process is simple to control, but the actual geometry cannot align with the target geometry for complex profiles
Solution Approach 1:
The patent applies feedback by implementing a closed-loop control system that continuously measures the workpiece geometry during forming and uses this information to adjust the oscillating movement parameters. The control system receives feedback about actual geometry deviations and automatically modifies the forming parameters to correct these deviations, achieving precise geometry alignment for complex profiles like toothing.
Solution Approach 2:
The patent makes the control system dynamic by enabling real-time adjustment of oscillating movement parameters based on workpiece geometry feedback. This dynamic control capability allows the system to handle complex profiles that require varying forming conditions throughout the process, while maintaining manageable complexity through automated control algorithms.
3Manufacturing precision
If the shaping tool profile moves only in one direction during forming, then the process is simpler, but the forming quality and precision are reduced
Solution Approach 1:
The patent applies periodic action by implementing an oscillating relative movement between the shaping tool profile and the workpiece during forming. The tool alternately moves forward and backward in a controlled oscillation pattern, which improves forming quality by distributing the forming load, reducing material resistance variations, and enhancing plastic deformation uniformity, thereby achieving superior forming precision for complex profiles.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method and mechanical arrangement enable precise production of workpiece profiles, such as toothing, by dynamically adjusting the forming process to match the target geometry, improving the machining accuracy and quality.
Implementation Method 1
a forming tool exerts a compressive force, on a workpiece to be formed, that is of such a size that the yield point of the workpiece material is exceeded
Implementation Method 2
an oscillating relative movement between the shaping tool profile and the workpiece (2) to be formed is carried out during the relative movement
Data Source
AI summary
In the context of a method for producing a profile on a plastically deformable, preferably cylindrical, workpiece by axial forming, a relative movement between a shaping tool profile provided on a forming tool and the workpiece to be formed is carried out during a forming process in order to produce a workpiece-side profile having a workpiece-side profile length. During the relative movement between the shaping tool profile and the workpiece to be formed, an oscillating relative movement between the shaping tool profile and the workpiece to be formed is created, in which a forming stroke and a return stroke in the opposite direction to the forming stroke are alternately carried out. The forming process in progress is varied with respect to the oscillating relative movement. A mechanical arrangement is designed to carry out the aforementioned method.