Opposed Track Joint Preform Forming for Precision
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Solution Overview
Problem
Current methods for producing torque transmission devices, such as fixed and constant velocity ball joints, are complex, costly, and result in significant waste and quality losses due to the need for complex machines and lengthy machining times, with limited precision and high material deformation.
Innovation Solution
The production of joint parts involves forming preforms with axially parallel grooves and projections, allowing for chipless deformation to create ball contact lines without machining, and surface hardening to achieve high torque transmission values with reduced tool wear and improved indexing precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If chip removal methods are used to produce ball raceways, then the tracks can be formed, but the process becomes complex, costly, and time-consuming with significant material waste
Solution Approach 1:
The patent replaces traditional mechanical chip removal processes with a plastic deformation process. A calibration tool with opposing deformation elements plastically deforms the preform material to form the ball raceways, eliminating the need for complex machining operations and achieving both high precision and productivity
Solution Approach 2:
The patent changes the physical state and properties of the material during processing. By heating the preform to elevated temperatures, the material becomes more pliable and easier to deform, allowing the calibration process to form precise raceways with reduced force and without material removal
2Manufacturing precision
If chip removal machining is used, then tracks are formed, but material flow lines are cut through causing quality losses in strength
Solution Approach 1:
The patent substitutes plastic deformation for mechanical cutting. The calibration tool deforms the preform material plastically to form the raceway geometry, preserving the continuous material flow lines and avoiding the strength reductions caused by machining cuts
Solution Approach 2:
The patent performs preliminary forming of the preform with approximate raceway geometry before final calibration. This preliminary action prepares the material in a way that minimizes deformation during calibration while maintaining material integrity and avoiding strength-critical machining operations
3Loss of substance
If hot-cold or warm-cold processes with preforms are used, then chipless production is achieved, but differing tools with opposing ball raceways are required and indexing precision is limited by machine guidance
Solution Approach 1:
The patent designs the calibration tool with universal features that can accommodate different preform variations. The tool incorporates self-aligning mechanisms and flexible positioning that allow it to function effectively across multiple production scenarios without requiring completely different tools for each case
Solution Approach 2:
The calibration process is designed to be self-correcting, where the tool automatically compensates for preform variations through self-aligning features and feedback mechanisms. This eliminates the need for complex external guidance systems and achieves high indexing precision through the tool's own design
4Manufacturing precision
If conventional machining processes are used, then tracks are formed, but tool wear is high and machining times are long
Solution Approach 1:
The patent replaces time-consuming mechanical machining with rapid plastic deformation. The calibration process forms the final raceway geometry in a single or few deformation strokes, eliminating prolonged machining operations and significantly reducing cycle time while maintaining precision
Solution Approach 2:
The patent utilizes temperature as a parameter to facilitate faster forming. By maintaining the preform at elevated temperatures during calibration, the material deforms more readily and quickly, reducing the time required to achieve precise raceway geometry without compromising accuracy
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 cost-effective, high-quality production with reduced machining times, increased torque transmission capabilities, and extended service life by minimizing deformation work and eliminating the need for precise machine guidance.
Implementation Method 1
hot-cold or warm-cold processes, a preform being produced within a forging procedure
Implementation Method 2
the required precision being achieved in a cold calibration process
Implementation Method 3
surface hardening to achieve high torque transmission values
Data Source
AI summary
A method for producing an internal or external part of a torque-transmitting opposed track joint, such as a fixed constant velocity ball joint, in which approximately axially parallel extending track bases of the joint tracks have curvatures which deviate in their axial course from the curvatures of the ball contact lines. The method is characterized in that in a first step a perform with approximately axially parallel extending grooves having lateral flanks is produced, and in a second step the perform is formed into a final joint part whereby the lateral flanks of the grooves are just partially formed to achieve the ball contact lines.