Gear Forging with Edge-Pressing Punch to Prevent Burrs
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Solution Overview
Problem
In gear forging, burrs often form at the edge of the surface opposite to the direction in which the material is pushed, leading to inefficiencies and inaccuracies in the manufacturing process.
Innovation Solution
A method and apparatus that incorporate a guide die and a second punch with a tooth pressing part to prevent burrs by ensuring continuous connection between the guide die and tooth profile die, allowing the second punch to cover and press down on the edge where external teeth are formed, and a housing part to manage excess material, reducing the risk of burr formation and improving surface finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a material is pushed into a tooth profile die by a punch to form external teeth, then the gear shape is formed, but burrs are formed at the edge of the surface opposite to the pushing direction
Solution Approach 1:
A second punch is introduced as an intermediary tool between the material and the tooth profile die. This second punch includes a tooth pressing part that presses the edge of the material during the forging process, preventing burr formation while allowing the gear shape to be formed accurately.
Solution Approach 2:
The second punch applies localized pressure only at the edge region of the material where burrs are likely to form. The tooth pressing part is positioned to contact only the peripheral edge, providing local constraint without interfering with the overall gear shaping process.
2Object-generated harmful factors
If a second punch is added to press down edges and prevent burrs, then burr formation is reduced, but the device complexity increases
Solution Approach 1:
The second punch combines multiple functions in a single tool: it supports the material during forging, presses the edges to prevent burrs, and allows excess material to be shed. This integration reduces the need for separate operations or additional complex mechanisms.
Solution Approach 2:
The second punch serves multiple purposes: it acts as a support for the material, a pressing tool for edge constraint, and a shedding mechanism for excess material. This multi-functionality reduces the overall complexity by eliminating the need for separate devices for each function.
3Manufacturing precision
If the tooth profile die through hole has a larger diameter, then the gear can be formed completely, but excess material causes burrs at the edge
Solution Approach 1:
The second punch is positioned and configured in advance to press the edge of the material before the forging process completes. The housing part is also designed beforehand to receive and shed excess material, preventing burr formation before it occurs.
Solution Approach 2:
The housing part of the second punch extracts excess material from the forging process by providing a designated space for it to shed. This separation of excess material from the main gear forming process prevents burrs while maintaining complete gear shape formation.
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 configuration effectively prevents burr formation, enhances the accuracy of gear shape, and reduces post-processing steps, thereby improving the productivity and quality of the gear forging process.
Implementation Method 1
pushing a material into a through hole of a tooth profile die from one side of the tooth profile die by a first punch... forming external teeth on the material
Implementation Method 2
pushing a second punch into the through hole of the guide die subsequently to the material, inserting a tooth pressing part formed on an outer peripheral part of the second punch into the tooth profile groove of the guide die to move the second punch along the tooth profile groove... the tooth pressing part of the second punch covers, when the material passes through the tooth profile groove of the tooth profile die, at least an edge of a region where external teeth are formed
Data Source
AI summary
The present disclosure provides a method for forging a gear capable of preventing burrs from being formed at an edge of the surface opposite to a direction in which a material in external teeth of the material is pushed. A first exemplary aspect is a method for moving the second punch along a tooth profile groove of the guide die to stack the material and the second punch in this order; and pushing the material and the second punch into a tooth profile groove of the tooth profile die in a stacked state to pass them therethrough, in which a tooth pressing part of the second punch covers at least an edge of a region where external teeth are formed on a surface of the material on the first punch side.