Gearwheel Axial Undercut via Tilted Tooth Forging
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Solution Overview
Problem
Existing methods for producing gearwheels with axial undercuts are complex and prone to faults due to the use of radially closing sliding tools, which require multi-part forming tools and are not accurate in production.
Innovation Solution
A method involving a blank with tilted teeth relative to the axis of rotation, allowing a forming tool to perform axial linear motions to introduce and size axial undercuts through a series of forging blows, eliminating the need for radially closing sliding tools and enabling the formation of axial undercuts without multi-part tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If radially closing sliding tools are used to form axial undercuts, then the gearwheel teeth can be formed with axial undercuts, but the tool complexity increases and production accuracy decreases
Solution Approach 1:
Instead of using complex radially closing sliding tools to form undercuts, the patent inverts the approach by tilting the teeth relative to the axis of rotation. This allows a simple axial forging tool to advance fully into the tooth flank sides and form undercuts through axial linear motion, eliminating the need for complex radial sliding mechanisms while improving production accuracy
Solution Approach 2:
The patent changes the dimensional approach by tilting the teeth at an angle to the axis of rotation. This angular orientation allows the forging tool to access the tooth flank sides axially, transforming the problem from a radial tool movement challenge into a simple axial forging operation, thereby reducing tool complexity and improving accuracy
2Reliability
If multi-part forming tools are used, then axial undercuts can be formed on teeth accessible from one side, but the susceptibility to faults increases
Solution Approach 1:
The patent merges the tooth formation and undercut creation into a single integrated axial forging operation. By tilting the teeth, the same axial forging tool that forms the tooth also creates the undercut in one continuous motion, eliminating the need for separate radially closing sliding elements and reducing fault susceptibility
Solution Approach 2:
Instead of using multiple separate tools (forming tool plus radial sliding elements), the patent inverts the approach by using a single axial forging tool with tilted teeth. This single-tool solution eliminates the interfaces and coordination issues between multiple parts, significantly reducing susceptibility to faults
3Ease of operation
If teeth are tilted relative to the axis of rotation, then axial linear motion can fully access tooth flank sides, but the blank geometry becomes more complex
Solution Approach 1:
The patent applies preliminary action by tilting the teeth in the blank before the forging operation. This pre-tilting ensures that during the axial forging process, the tool can advance fully into the tooth flank sides without obstruction, enabling complete access and proper undercut formation. The tilted geometry is intentionally created in advance to facilitate the subsequent axial forming operation
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 simplifies the production of gearwheels with axial undercuts, reducing tool complexity and improving production accuracy by allowing axial undercuts to be formed using only axial linear movements, resulting in a more reliable and precise gearwheel manufacturing process.
Implementation Method 1
performance of a first axial forming operation, in particular in the form of a first axial forging blow, by means of which a preliminary form of the at least one axial undercut is introduced on the tooth flank sides
Implementation Method 2
performance of a second forming operation, in particular in the form of a second forging blow, by means of which the gearwheel is bent in such a way that the teeth are bent, preferably back into the vertical
Data Source
AI summary
A method for producing a gearwheel having an axis of rotation and a tooth system. The teeth have an axial undercut on the tooth flank sides thereof. A blank is provided having a tooth system, wherein the teeth of the tooth system are provided so as to be tilted relative to the axis of rotation such that a forming tool can advance substantially fully into the tooth flank sides of the teeth through an axial linear motion along the axis of rotation. A preliminary form of the at least one axial undercut can be provided on the tooth flank sides. A first axial forming operation is performed in the form of a first axial forging blow via which a preliminary form of the at least one axial undercut is introduced on the tooth flank sides or an already existing preliminary form of an axial undercut is sized for accuracy.