Coupling Element Spur Toothing Axial Projection Forming
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Solution Overview
Problem
The existing methods for forming spur toothings in coupling elements, such as those in wheel bearing units, require high forces and are costly due to the need for precise geometry and significant material displacement, leading to inefficiencies in the forming process and accuracy of the teeth.
Innovation Solution
A spur toothing design where a section projecting axially from the coupling element is formed with converging contours, reducing the material that needs to be displaced and allowing for controlled material flow into the forming die, thereby reducing the required forces and improving the precision and quality of the teeth formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the spur toothing is formed by cold-forming with significant material displacement from the axial direction, then the teeth can be formed directly on the coupling element surface, but the forming forces required are very high and material escapes radially outward
Solution Approach 1:
The coupling element is segmented into two functional parts: a base coupling element and a separately formed section that projects axially outward. The spur toothing is formed only on this section, which contains only the material necessary for tooth formation. This segmentation isolates the forming process to a localized area with minimal material, reducing the forming forces while maintaining tooth precision.
Solution Approach 2:
The invention transitions from forming teeth by displacing material radially outward from the axial surface to forming teeth by displacing material axially within a dedicated section that projects in the axial direction. This dimensional change allows the forming process to work with a smaller, more controlled material volume, reducing the required forming forces while maintaining manufacturing precision.
2Ease of manufacture
If high forming forces are used to form teeth from a large material accumulation, then the teeth can be formed directly on the coupling element, but a large part of the material escapes radially outward and does not flow into the forming die
Solution Approach 1:
The coupling element is divided into a base structure and a separate section that contains only the material needed for tooth formation. This section projects axially outward and is designed with contours that guide material flow during forming. By segmenting the material into a dedicated forming section, material escape is minimized as the material is already positioned within the forming zone.
Solution Approach 2:
The section is pre-formed with specific contours before the tooth forming process. These contours are designed to guide and control the material flow during the subsequent forming operation, ensuring that material flows into the forming die in a controlled manner rather than escaping radially outward. This preliminary shaping of the material reduces material loss during forming.
3Power
If the material accumulation is restricted to a minimum in the section, then the forming forces are reduced and machines with lower power can be used, but the section must be designed with specific contours to control material flow
Solution Approach 1:
The coupling element is segmented into a simple base structure and a separate section with optimized contours. This segmentation allows the complex contouring to be localized only to the section where material control is needed, while the rest of the coupling element remains simple. The section contains minimal material and is designed with contours that control material flow, enabling the use of lower power forming machines.
Solution Approach 2:
The complex contouring is applied locally only to the section that requires precise material control during forming. The base coupling element maintains a simple geometry, while the section has optimized contours that guide material flow. This local application of complexity reduces the overall device complexity while achieving the goal of reduced forming forces and machine power requirements.
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
This approach allows for the cost-effective production of spur toothings with higher load-bearing components using machines with lower power characteristics, resulting in better-formed teeth and improved torque transmission efficiency.
Implementation Method 1
the material is plastically displaced by feeding forming dies from the axial direction
Implementation Method 2
the spur toothings are formed by cold-forming of certain regions of the material of the coupling elements
Data Source
AI summary
The invention relates to a spur toothing on at least one coupling element for transmitting torques about a rotational axis, said spur toothing axially engaging with a corresponding mating cutting. The face cutting is provided with teeth from a material of the coupling element that has been plastically shaped in an at least partially noncutting manner.