Rotating Mold Core Ejection for Spiral Bevel Gear Forging

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Solution Overview

Problem

Conventional methods for forging spiral bevel gears are inefficient due to material wastage, complex processing, and structural weakness, as well as difficulties in stripping the gear from the mold without damaging the punch rod or mold core.

Innovation Solution

A spiral bevel gear forging apparatus comprising a first mold unit with a rotatable mold core and a push mechanism that allows the mold core to rotate about a punch rod, enabling direct ejection of the forged blank without additional cutting processes, thus maintaining the integrity of the mold and punch rod.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a rotatable punch rod is used to push the spiral bevel gear out of the mold, then the gear can be stripped from the mold, but the punch rod becomes complicated with transmission components and may have its strength destroyed

Engineering Contradiction:

Improvestripping capabilityVSAvoidpunch rod structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

Instead of rotating the punch rod to strip the gear, the invention inverts the approach by rotating the mold core while keeping the punch rod stationary. This reversal eliminates the need for transmission components on the punch rod and preserves its structural strength, while still achieving the stripping function through the rotation of the mold core.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention extracts the rotation function from the punch rod and transfers it to the mold core. By separating the rotation capability from the ejection function, the punch rod remains a simple, strong pushing element without any transmission components, while the mold core handles the rotation necessary for stripping the spiral bevel gear.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of manufacture

If conventional cutting process is used to form spiral bevel gears, then the gears can be manufactured, but material is wasted and processing time is lengthy

Engineering Contradiction:

Improvemanufacturing capabilityVSAvoidprocessing efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The invention replaces the conventional mechanical cutting process with a forging process. Instead of removing material through cutting, the blank is forged directly into the spiral bevel gear shape using the rotating mold core and punch rod system. This substitution eliminates material wastage and significantly reduces processing time while maintaining manufacturing capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9403207B2Spiral bevel gear forging apparatus

Publication Date: 2016.08.02 METAL INDS RES & DEV CENT

AI summary

A spiral bevel gear forging apparatus for forging a blank includes a first mold core having a mold cavity for receiving the blank, a first punch rod inserted movably into the first mold core and having a positioning end extending into the mold cavity for releasable engagement with a bottom of the blank, at least one push mechanism, and a drive mechanism. When the drive mechanism is operated to move from a non-ejecting to an ejecting position, the push mechanism is actuated to drive the first mold core to rotate about the first punch rod, and the first punch rod is actuated to move relative to the first mold core such that the positioning end thereof is moved out of the mold cavity for ejecting the blank out of the first mold core.