Internal Impeller Gear Cold-Forming with Synchronized Oscillation
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Solution Overview
Problem
Current methods for producing internal impeller gearing face challenges in achieving high precision, efficiency, and large toothing depths, particularly in ring gears, with existing cold-forming methods struggling to meet accuracy and load-bearing capacity requirements.
Innovation Solution
A method involving a device that uses multiple embossing tools to cold-form internal impeller toothing in a tubular workpiece with varying rotational speed and synchronized radial oscillations, allowing for precise and efficient production of deep toothings without chip removal, except in calibration steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cold forming is used to produce internal impeller gear teeth, then manufacturing efficiency and productivity are improved, but achieving high precision and large tooth depths becomes difficult
Solution Approach 1:
The gear tooth formation process is divided into multiple sequential embossing steps using several embossing tools arranged in a circle, each tool contributing to different portions of the tooth profile. This segmentation allows complex deep tooth formations to be achieved through multiple controlled passes rather than a single operation, resolving the contradiction between productivity and precision.
Solution Approach 2:
The workpiece undergoes intermittent rotation with periodic stopping at predetermined angular positions during the embossing process. This periodic action allows multiple embossing tools to sequentially form teeth at different locations, enabling high productivity while maintaining precision through controlled, repeated formatting operations.
2Productivity
If multiple embossing tools are used to increase productivity, then manufacturing efficiency is improved, but device complexity increases
Solution Approach 1:
Multiple embossing tools are combined in a single circular arrangement around the workpiece, all acting simultaneously on different angular positions. This merging of multiple tools into one integrated setup increases productivity without proportionally increasing overall device complexity, as the tools share common mounting and control structures.
Solution Approach 2:
The embossing tools are arranged symmetrically in a circle around the workpiece axis, creating an equipotential geometric configuration. This symmetric arrangement simplifies the device structure by making all tool positions equivalent, allowing standardized tool holders and uniform spacing, thereby reducing complexity while maintaining high productivity.
3Manufacturing precision
If high precision is achieved through multiple formatting passes, then manufacturing precision is improved, but production time increases
Solution Approach 1:
The embossing process is designed to form all gear teeth continuously in a single workpiece rotation cycle. Multiple embossing tools act simultaneously on different angular positions, and the workpiece rotates through all positions in one continuous motion. This eliminates the need for multiple separate formatting passes, achieving high precision without increasing production time.
Solution Approach 2:
The workpiece is pre-positioned and rotated to predetermined angular positions before each embossing operation. This preliminary positioning ensures that each embossing tool engages the workpiece at the exact correct location, enabling high precision to be achieved in a single pass without requiring multiple corrective formatting operations that would increase production time.
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 approach enables the production of impeller gearing with high precision, great dimensional stability, and high surface quality, achieving large toothing depths and maintaining material strength, reducing the need for post-processing and minimizing hardening distortion.
Implementation Method 1
The thin-walled hollow part sits on an externally profiled mandrel and is cold-formed by at least one profiling tool that acts abruptly on the hollow part from the outside
Data Source
Figure 1~2
Figure 3~6
Figure 4~5
AI summary
The invention relates to a method for producing a ring gear (la) provided with an internally toothed section (6), wherein a workpiece (1) has a tubular section with a longitudinal axis (Z), which defines the term "radial" used below. By means of N ≥2 embossing dies (21, 22,...), each of which is moved to a working position during execution of the method, the workpiece is processed to produce the internally toothed section on the inside of the tubular section. The workpiece rotates about said longitudinal axis at a rotational speed that varies with time and the at least one embossing die (23) located in the working position each radially oscillates, said movement being synchronised with the rotational movement. The at least one embossing die located in the working position processes the workpiece (1) repeatedly.