Frontal Toothing on Wheel Hub Inner Ring
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Solution Overview
Problem
Existing methods for forming frontal toothing on wheel hub inner rings require complex tools and fail to ensure absolute tooth profile constancy, which is necessary for high torque transmission.
Innovation Solution
A method using a single massive creator tool with a varying radius profile for the complementary toothing, applied in a sequence after forming the upset collar, to achieve consistent and accurate tooth formation through plastic deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a complex tool with multiple elements is used to form the frontal toothing during collar deformation, then the toothing can be formed simultaneously with the upset collar, but the tool complexity increases and absolute tooth profile constancy cannot be achieved
Solution Approach 1:
The process is divided into two separate sequential operations: first forming the upset collar, then forming the frontal toothing on the already-formed collar. This segmentation allows each operation to use a simpler, dedicated tool rather than a complex multi-element tool attempting to perform both functions simultaneously.
Solution Approach 2:
The upset collar is formed in advance before the frontal toothing is created. This preliminary action prepares the workpiece in a suitable state for the subsequent toothing formation, allowing each step to be optimized independently with simpler tools.
2Manufacturing precision
If a traditional orbital forming tool is used to form the frontal toothing, then the forming process can be completed, but the tooth profile constancy and dimensional accuracy are insufficient for high torque transmission requirements
Solution Approach 1:
Instead of using a complex multi-element tool attempting to form both the collar and toothing simultaneously, the invention uses a simple single-element tool to form the toothing on an already-formed collar. This inverted approach prioritizes precision over simultaneous productivity.
Solution Approach 2:
The frontal toothing is formed by copying the profile from a simple single-element tool onto the upset collar. This copying process ensures high tooth profile constancy and dimensional accuracy, as the tool geometry can be precisely controlled and replicated.
3Manufacturing precision
If a single massive creator tool is used to form the frontal toothing after collar formation, then higher dimensional accuracy and tooth profile constancy are achieved, but the process requires two separate forming steps
Solution Approach 1:
The manufacturing process is segmented into two distinct steps: first forming the upset collar, then forming the frontal toothing. This segmentation enables each step to use a simplified, single-element tool, achieving high precision while maintaining process efficiency through clear separation of operations.
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 method ensures higher dimensional accuracy and constancy of the teeth, leading to more effective, quieter, and higher capacity torque transmissions with lower energy consumption.
Implementation Method 1
forming a frontal toothing on an inner ring of a wheel hub by means of plastic deformation
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method including the steps of forming an inner ring (3) of a wheel hub (1), by joining a spindle (7) and an insert ring (8) fitted onto the spindle, on the side of a first end (9) of the spindle; axially blocking the insert ring on the spindle by plastically deforming the first end of the spindle so as to form an upset collar (10) therewith, which axially protrudes from the insert ring; and once the step of forming the upset collar has finished, frontally obtaining on the collar, on the side opposite to the insert ring a frontal toothing (5) by means of a single creator tool (11) provided, towards the collar, with a toothing (12) which is complementary to that to be obtained, by impressing onto the collar, in sequence, one or more teeth (13) of the complementary toothing, which have ridges (14) with a rounded profile having a curvature radius (R) varying in the direction of an axis of symmetry (A1) of the tool (11).