CV Joint Outer Member Forging With Groove Phase Alignment
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Solution Overview
Problem
The existing forging methods for outer joint members of constant velocity universal joints face challenges in stably forming track grooves with an arc shape inclined in the circumferential direction and varying diameters, leading to alignment issues and potential forming failures.
Innovation Solution
A forging apparatus and method that includes a phase alignment mechanism with convex portions and a rotary mechanism to align the phases of grooves in the pre-processing material with the track groove forming surfaces of the punch set, allowing for precise alignment and stable formation of the outer joint member using an existing ironing mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If phase alignment is performed using existing positioning mechanisms with pins and springs, then the pre-processing material can be positioned, but the phases of track forming grooves and track groove forming surfaces cannot be reliably aligned, leading to forming failures
Solution Approach 1:
The phase alignment pins are positioned in advance at predetermined locations on the punch set before the ironing process begins. This preliminary positioning ensures that when the pre-processing material is inserted, the grooves are already aligned with the correct phases, eliminating alignment errors during the actual forming operation.
Solution Approach 2:
The invention replaces the complex spring-based pressing member and stopper mechanism with a simpler pin-based positioning system. The phase alignment pins directly engage with corresponding features on the pre-processing material to establish precise phase relationships, substituting mechanical complexity with a more reliable geometric constraint system.
2Manufacturing precision
If a complex positioning mechanism with pressing members and stopper mechanisms is used to align phases, then alignment can be attempted, but the device complexity increases and alignment reliability decreases
Solution Approach 1:
The invention extracts and removes the unnecessary pressing member and stopper mechanism from the positioning system. Only the essential phase alignment pins are retained, which directly perform the alignment function without requiring additional components to apply pressure or prevent movement. This extraction eliminates complexity while maintaining alignment precision.
Solution Approach 2:
The phase alignment pins are designed to automatically self-align the pre-processing material grooves with the punch set forming surfaces through their predetermined positioning locations. The system uses its own geometric features rather than external forcing mechanisms, allowing the alignment to occur naturally through the engagement of pin and groove features.
3Ease of manufacture
If existing ironing mechanisms are used without phase alignment improvements, then the apparatus can be used as-is, but forming failures and die breakage occur due to misalignment
Solution Approach 1:
The phase alignment pins are pre-installed on the punch set before the ironing operation begins. This preliminary setup ensures that when the pre-processing material is inserted into the die, the grooves are already in the correct phase relationship with the forming surfaces, preventing misalignment-induced failures during the actual forming process.
Solution Approach 2:
The phase alignment pins serve as intermediary elements between the punch set and the pre-processing material. These pins mediate the alignment relationship by engaging with corresponding features on both components, ensuring proper phase alignment is established before the main forming action occurs, thereby preventing forming failures and die breakage.
Data Source
AI summary
A forging apparatus includes an ironing mechanism and a phase alignment mechanism. The ironing mechanism includes: a punch set, which is fitted into a cylindrical portion of a pre-processing material to be formed into the outer joint member, and is radially expandable and contractible, the cylindrical portion having grooves formed in an inner peripheral surface thereof; and a die having a hole into which the cylindrical portion is press-fitted. The phase alignment mechanism is configured to align phases of the grooves in the inner peripheral surface of the pre-processing material and phases of track groove portion forming surfaces of the punch set with each other before the pre-processing material is fitted to the punch set.