Roll Spinning Gear Forming With Constant Speed Ratio Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional roll spinning forming of toothed parts faces challenges in achieving accurate tooth division due to the complex structure of the device, leading to inconsistent pitch and poor forming quality, as the rotation of the blank is not controlled effectively.
Innovation Solution
A roll spinning forming device and method that ensures a constant rotating speed ratio between the blank and the roller by using a spindle, mandrel, driving and driven synchromesh gears, a telescopic constant speed universal joint assembly, spring mechanism, and servo motor assembly, allowing for synchronized and controlled rotation and movement of the roller relative to the blank.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If active rotation of the roller is adopted with free rotation of the blank, then the forming process can be completed, but the pitch changes constantly and accurate tooth division cannot be achieved
Solution Approach 1:
The patent transforms the static roller tooth shape design into a dynamic solution by implementing synchronized rotation control. The roller and blank rotate with a constant speed ratio through the gear mechanism, allowing the roller tooth shape to be standardized while achieving accurate tooth division through dynamic speed coordination.
Solution Approach 2:
The patent introduces a gear mechanism as an intermediary between the roller drive and blank rotation. The driving gear on the roller and driven gear on the blank create a constant speed ratio relationship, mediating the motion control to ensure accurate tooth division without complex roller design.
2Manufacturing precision
If the roller axis is close to the blank axis continuously, then the forming process proceeds, but the pitch changes constantly and precision deteriorates
Solution Approach 1:
The patent implements a feedback control mechanism through the gear system. The gear teeth engagement provides inherent feedback that maintains the constant speed ratio, ensuring the roller and blank rotate in precise synchronization, thereby maintaining consistent pitch throughout the forming process.
Solution Approach 2:
The patent replaces the complex mechanical control of free rotation with a gear-based mechanical transmission system. This substitution provides inherent motion control through gear tooth engagement, eliminating the need for complex external control mechanisms while ensuring constant speed ratio.
3Strength
If conventional roll spinning forming is used, then production can proceed, but the fiber tissue is cut off and part strength is reduced
Solution Approach 1:
The patent applies preliminary action by pre-heating the blank before forming. This preliminary thermal treatment makes the material more pliable, allowing it to be formed into toothed shapes without cutting the fiber tissue, thereby maintaining part strength while enabling continuous production.
Data Source
AI summary
Disclosed is a roll spinning forming device for a toothed part. The device is mounted on a machine tool body. A blank, a mandrel and a driving synchromesh gear are mounted on a machine tool spindle. A driven synchromesh gear and a roller are arranged in parallel on the spindle. The driven synchromesh gear and the roller are connected by a telescopic constant speed universal joint and rotate at a same angular speed. The driven synchromesh gear is driven by a spring mechanism in the radial direction, and the roller is driven by a servo motor assembly in the radial direction. Further disclosed is a roll spinning forming method for a toothed part, the rotating speed of the blank is maintained to be matched with the rotating speed of the roller according to a gear ratio during the movement of the roller toward the blank.