Helical Spline Stamping Press Using Force-to-Rotation Tooling
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Solution Overview
Problem
The manufacturing of helical gear or spline forms on disc-shaped components is complex and costly, requiring lengthy processes like hobbing and additional finishing operations, and is difficult to implement on disc-shaped components due to compressive forces involved.
Innovation Solution
A method using a stamping press with helical shaped punch and die tooling that transforms vertical press force into rotational motion to form a helical outer diameter spline without external rotating tooling, utilizing a press stripper as a drive plate and gas springs to impart rotation on the punch, allowing for high-volume production of disc-shaped components with accurate helical tooth forms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional hobbing or cutting processes are used to manufacture helical gear forms, then accurate helical tooth geometry can be achieved, but the manufacturing process becomes lengthy and costly with additional finishing operations required
Solution Approach 1:
The helical tooth form is pre-formed on the punch tooling before the stamping operation. The punch already contains the complete helical geometry, allowing the feature to be formed in a single pressing action rather than requiring multiple sequential operations like hobbing followed by finishing
Solution Approach 2:
The invention combines the forming of the helical tooth geometry with the blank stamping operation into a single process step. The punch simultaneously stamps the blank and forms the helical features, merging what would traditionally be separate operations into one integrated process
2Ease of manufacture
If rolling processes are used for helical splines on solid shafts, then the compressive forces can form the helical features, but it becomes difficult to implement on disc-shaped components
Solution Approach 1:
Instead of applying compressive force to form the helical features (as in traditional rolling), the invention uses a punch with pre-formed helical geometry that presses into the blank. The force application is inverted from the traditional approach, allowing the process to work on disc-shaped components rather than solid shafts
Solution Approach 2:
The helical tooth form is copied from the punch tooling onto the blank. The punch serves as a template that reproduces the exact helical geometry needed, transferring the form from tooling to workpiece in a single pressing action
3Ease of operation
If external rotating driving means are used to rotate the punch and die tooling, then rotational motion can be achieved, but capital equipment costs and device complexity increase
Solution Approach 1:
The press stripper is made to serve dual functions: it acts as both the traditional stripper that removes the formed part from the die, and as a drive plate that transmits rotational motion to the punch. This self-service approach eliminates the need for separate external rotating drivers
Solution Approach 2:
The press stripper is given multiple functions within the same component. It simultaneously performs the stripping function (removing the formed part) and the driving function (rotating the punch through helical gear interfaces), reducing the total number of components needed
4Device complexity
If gas springs are used to apply vertical load to the drive plate, then rotational moment can be imparted to the punch without external motors, but the force application mechanism becomes more complex
Solution Approach 1:
Gas springs are used to provide the vertical loading force on the drive plate. This pneumatic approach replaces the need for mechanical force transmission mechanisms, using gas pressure to directly apply the necessary force for rotating the punch through the helical gear interfaces
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 the production of disc-shaped components with external helical spline or gear forms in a cost-efficient manner, achieving accurate geometry and quality surface finish without the need for additional finishing operations or external mechanized drivers, thereby reducing capital expenses and manufacturing time.
Implementation Method 1
The upper portion includes the upper die shoe and a stripper which has been configured to operate as a drive plate using a first helical gear interface to impart a rotational moment on the punch from a vertical load applied by gas springs
Data Source
AI summary
A press assembly for forming outer helical splines on a blank includes an upper press shoe assembly and a die shoe assembly. The upper press shoe assembly includes an upper rotatable portion rotatable relative to an upper stationary portion. The lower portion includes a lower rotatable portion rotatable relative to a lower stationary portion. The unfinished blank is supported by the lower portion, and the upper portion is moveable into engagement with the blank. The upper rotatable portion joins with the lower rotatable portion for conjoint rotation relative to the upper and lower stationary portions via upper and lower helical meshes defined between the rotatable and stationary portions. The helical meshes convert downward force into rotation and translation of the blank into a spline forming die of the lower stationary portion to create the outer helical splines.