Gear Tooth Root Strengthening via Electromagnetic Punch Impact
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Solution Overview
Problem
Current shot peening techniques, such as ultrasonic and laser shot peening, are inefficient and costly for strengthening the tooth root of gears due to complex geometries and high operational costs, limiting their effectiveness and industrial applicability.
Innovation Solution
A device comprising a charging and discharging control system, a punch driver with a coil generating a pulsed magnetic field, a positioner, and an actuator, which allows the punch to reciprocate and rotate the gear, enabling continuous impact on the tooth root to introduce a residual compressive stress layer, thus overcoming the limitations of existing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If shot peening strengthening technique is used to strengthen the tooth root, then the tooth root can be strengthened, but the efficiency is low and the effect is poor due to complex geometries and narrow spaces
Solution Approach 1:
The patent replaces the traditional mechanical shot peening system with an electromagnetic impact system. A coil generates a pulsed magnetic field that drives a punch to reciprocate and impact the tooth root. This substitution allows the impactor to penetrate into the narrow tooth root space and follow complex geometries, achieving both high strength and high efficiency that were contradictory in traditional shot peening
Solution Approach 2:
The patent employs dynamic motion of the punch through reciprocating movement driven by the pulsed magnetic field. The punch can dynamically adapt its position to follow the complex geometry of the tooth root, enabling effective strengthening in narrow spaces while maintaining high processing efficiency
2Strength
If phase transformation strengthening or chemical strengthening is used, then the tooth root can be strengthened, but the process is complicated and surface accuracy deteriorates due to large deformation
Solution Approach 1:
The patent replaces thermal and chemical processes with a mechanical impact process driven by electromagnetic force. The pulsed magnetic field drives the punch to deliver controlled mechanical impacts that introduce residual compressive stress without the high temperatures and chemical reactions that cause surface deformation and accuracy loss
Solution Approach 2:
The patent changes the strengthening mechanism from thermal/chemical parameters to mechanical impact parameters. By controlling the frequency, amplitude, and duration of the pulsed magnetic field, the system achieves precise control over the impact force, introducing residual compressive stress while maintaining surface accuracy
3Strength
If laser shot peening is used, then the tooth root can be strengthened, but the cost is high and the area processed per unit time is limited
Solution Approach 1:
The patent replaces the expensive laser system with an electromagnetic impact system. The coil-driven punch mechanism achieves high processing speeds by rapidly reciprocating under pulsed magnetic field control, processing the entire tooth root area simultaneously rather than the limited area processing of laser methods, thereby reducing cost and increasing productivity
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 solution enables high-efficiency and stable strengthening of the tooth root, unaffected by complex geometries and narrow spaces, improving the bending fatigue strength of gears while reducing heat generation and operational costs.
Implementation Method 1
a coil generating a pulsed magnetic field
Data Source
AI summary
A device for performing strengthening treatment on a tooth root of a gear, a punch driver, a tooth root strengthening treatment device and a punch moving device are provided according to the present application. The device for performing the strengthening treatment on the tooth root of the gear according to the present application can impact a tooth root of a gear to be processed continuously under the action of the punch driver, and has a high efficiency while having a stable effect. The device in the present application is not limited by a complicated geometrical shape and a narrow space of the tooth root. Thus, it may be known that the devices according to the present application can address the issue of a low efficiency and poor effect in a current shot peening technique during performing the strengthening treatment on the tooth root.