Rolling Toothing Profile Forming for Simpler Cold-Press Tooling
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Solution Overview
Problem
Existing methods for producing toothed components, such as gear racks, are complex due to the intricate tool devices and processes required, which complicates the manufacturing process and tool structure.
Innovation Solution
A method involving a tool device with a vertically movable pressing part and a rotational body connected via a joint rod, where the rotational body rolls along the component blank to form the toothing profile, simplifying the tool structure and process by using fewer components and allowing for efficient production of various toothings with minimal wear and precise profile formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional cold forming methods are used with multiple spaced components, then the component can be shaped according to geometry, but the tool device structure becomes complex and manufacturing process becomes complicated
Solution Approach 1:
The patent combines multiple spaced forming components into a single rotational body that rolls along the component blank. Instead of using multiple separate pressing tools positioned at different locations, the invention uses one rotational body that simultaneously forms the toothing profile through rolling contact, thereby simplifying the tool device structure while maintaining manufacturing precision
Solution Approach 2:
The patent introduces a rotational body that moves from a static pressing tool to a dynamic rolling element. The rotational body rotates during the forming process, converting the pressing motion into a rolling motion that naturally conforms to the component blank geometry, simplifying the overall tool structure while achieving precise toothing profiles
2Manufacturing precision
If multiple spaced components are used in the tool device, then the component can be held and shaped, but the manufacturing efficiency decreases and production becomes less efficient
Solution Approach 1:
By merging multiple forming operations into a single rotational body, the patent enables all toothing profile formation to occur in one continuous rolling action rather than requiring multiple separate pressing steps, thereby improving manufacturing efficiency without compromising the accuracy of the toothing profile
Solution Approach 2:
The rotational body continuously rolls along the component blank during the forming process, maintaining constant contact and forming action throughout the operation. This continuous rolling action eliminates idle time between pressing steps and ensures uninterrupted formation of the toothing profile, enhancing productivity while maintaining precision
3Manufacturing precision
If a complex tool device with multiple components is used, then the component can be formed, but the wear of components increases and maintenance becomes more frequent
Solution Approach 1:
By consolidating multiple spaced components into a single rotational body, the patent reduces the total number of contact surfaces and potential wear points. The unified rotational structure distributes the forming load more evenly, reducing localized wear and improving the reliability and service life of the tool device while maintaining toothing profile quality
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 significantly simplifies the tool device structure and manufacturing process, enabling efficient production of precise toothing profiles with minimal wear and the ability to produce different toothings by exchanging only the rotational body, thereby increasing manufacturing efficiency and allowing for robust mounting and formation of irregular profiles.
Implementation Method 1
the rotational body is pressed in the direction of the component blank during the movement of the pressing part in the movement direction and rolls along the component blank so that the toothing profile is formed
Implementation Method 2
a rotational body and a joint rod that couples the rotational body with the pressing part, wherein the joint rod connects the rotational body to the pressing part in such a way that when the pressing part is moved vertically to form the toothing profile, the rotational body is pressed in the direction of the component blank
Implementation Method 3
a component blank is inserted into a mounting of a tool device to receive a pressing force when a pressing part of the tool device moves in a vertical movement direction
Implementation Method 4
the toothing profile is formed in a plurality of cold forming stages, wherein each cold forming stage has a rotational body coupled to the pressing part via a joint rod
Data Source
AI summary
A method for producing a component which has a toothing profile includes, in a first step, inserting a component blank into a mounting of a tool device configured to receive a pressing force during a movement of a pressing part of the tool device in a vertical movement direction, and, in a second step, pressing the toothing profile into the component blank using a rotational body which is coupled to the pressing part via a joint rod, when the pressing part is moved in the movement direction, the rotational body is pressed in a direction of the component blank and rolls along the component blank such that the toothing profile is formed.