Helical Gear Extrusion With Combined Axial and Peripheral Motion
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Solution Overview
Problem
Existing methods for manufacturing helical toothings, such as the Samanta method, often require post-processing due to insufficient toothing quality, which affects the efficiency and precision of gear production.
Innovation Solution
A forming method involving axial and peripheral movements of a forming tool with a shaping helical toothing relative to a cylindrical workpiece blank, utilizing adjustable process parameters and reversible movements to produce high-quality helical toothings, including involute gear teeth and splines, through extrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the Samanta method is used to manufacture helically-toothed gears with axial pressing through a die, then the manufacturing process is simple and straightforward, but the toothing quality is insufficient and requires post-processing
Solution Approach 1:
The patent applies dynamics by superimposing a peripheral movement component on the axial forming movement. The forming tool and workpiece blank move relative to each other not only in the axial direction but also in the peripheral direction, creating a combined motion path that enables high-quality helical toothing formation in a single pass without requiring post-processing operations.
Solution Approach 2:
The patent transitions from one-dimensional axial pressing to two-dimensional combined movement by adding the peripheral direction component. This dimensional expansion allows the forming tool to create precise helical toothings while maintaining process simplicity, resolving the contradiction between quality and complexity.
2Manufacturing precision
If conventional extrusion methods are used with only axial movement, then the device structure is simple, but the machining precision and toothing quality are insufficient
Solution Approach 1:
The patent implements dynamic motion control by coordinating axial and peripheral movements of the forming tool and workpiece blank. This dynamic combined movement approach achieves high machining precision for helical toothings while managing device complexity through synchronized control of the two movement components.
Solution Approach 2:
The patent utilizes parameter changes by adjusting the speed ratio between axial relative speed and peripheral relative speed based on the helix angle requirements. This parameter optimization enables precise control of toothing quality while maintaining efficient process operation.
3Manufacturing precision
If the forming tool and workpiece blank move only in axial direction, then the process control is simple, but the helical toothing quality is insufficient for high-precision applications
Solution Approach 1:
The patent achieves high helical toothing quality through dynamic coordination of axial and peripheral movements. The automated control system manages the combined motion path, superimposing peripheral movement on axial forming movement to create precise helical geometries without compromising process automation.
Solution Approach 2:
The patent employs feedback mechanisms to monitor and adjust the speed ratio between axial and peripheral movements during the forming process. This feedback control ensures consistent helical toothing quality by maintaining the correct kinematic relationship between the two movement components throughout 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
Enables high-quality manufacture of various gear geometries with improved machining precision and efficiency, suitable for producing external and internal helical toothings on shafts and gear wheels, with digital control for enhanced process management.
Implementation Method 1
forming method for producing a helical toothing of a cylindrical workpiece by extrusion
Data Source
AI summary
In the context of a forming method for producing a helical toothing of a cylindrical workpiece by extrusion, a relative movement of a forming tool and of a workpiece blank carried out in a peripheral direction of the forming tool and of the workpiece blank is superimposed on an axial forming movement of the forming tool and of the workpiece blank. Due to a forming relative movement of the forming tool and of the workpiece blank resulting from the mutual superimposition of the axial forming movement and the forming movement in the peripheral direction, the helical toothing of the workpiece is produced on the workpiece blank, in that the forming tool engages, with a shaping helical toothing, in the workpiece blank during the resulting forming relative movement. A forming machine is designed to carry out the aforementioned method.