Helical-Tooth Sintered Material Sizing Under Thrust Bearing Limits
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Solution Overview
Problem
Existing sizing devices face limitations in applying high pressing forces due to thrust bearing load capacity constraints, leading to difficulties in achieving high dimensional accuracy in sintered materials with helical teeth.
Innovation Solution
A sizing device and method that includes a die, first and second punches, and a thrust bearing, where the first punch is rotatably supported and stopped at a predetermined position to avoid exceeding the thrust bearing's load capacity, allowing high pressing forces to be applied, and a sintered material with helical teeth having low tooth profile and trace errors is produced.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high pressing forces are applied to improve dimensional accuracy of helical teeth, then manufacturing precision improves, but the thrust bearing load capacity is exceeded
Solution Approach 1:
A sizing die is introduced as an intermediary component between the pressing device and the sintered material. The sizing die includes a sizing cavity with helical teeth that mesh with the helical teeth of the sintered material, allowing the pressing force to be applied through a mechanical advantage system rather than directly through the thrust bearing, thereby enabling high pressing forces without exceeding bearing capacity
Solution Approach 2:
The pressing device is designed to apply dynamic pressing forces with controlled progression. The pressing force increases gradually during the sizing process, allowing the thrust bearing to handle the load within its capacity while still achieving the required dimensional accuracy through the cumulative effect of the pressing force
2Reliability
If the thrust bearing load capacity is respected, then device reliability is maintained, but the pressing force is limited and manufacturing precision deteriorates
Solution Approach 1:
The sizing die acts as a mechanical intermediary that amplifies the pressing force through its cavity structure. The helical teeth in the sizing cavity engage with the helical teeth of the sintered material, creating a meshing action that multiplies the effective pressing force while keeping the actual load on the thrust bearing within acceptable limits
Solution Approach 2:
The sizing cavity is designed with curved surfaces and helical geometries that optimize the distribution of pressing forces. The helical shape of the teeth and the curved profile of the cavity walls allow for progressive engagement and force distribution, enabling high pressing forces to be applied through the structure without concentrating excessive load on the thrust bearing
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 enhances the dimensional accuracy of sintered materials by reducing tooth profile and trace errors, enabling the application of high pressing forces without exceeding the thrust bearing's load capacity.
Implementation Method 1
a thrust bearing that rotatably supports the first punch
Implementation Method 2
one of an inner peripheral surface of the through-hole of the die and an outer peripheral surface of the first punch has a first helical tooth that meshes with the helical tooth of the sintered material
Data Source
AI summary
A cylindrical sintered material made of metal, in which one of an inner peripheral surface and an outer peripheral surface of the sintered material includes: a plurality of helical teeth arranged in parallel along a circumferential direction of the sintered material; and a sizing mark provided on at least a part of a tooth bottom surface, a tooth surface, and a tooth tip surface of each of the helical teeth, the helical tooth has a tooth profile error less than or equal to 6 μm, and the helical tooth has a tooth trace error less than or equal to 27 μm.