Tooth Crowning Die Forming for Annular Gear Precision
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing crowning forming methods require multiple processes and equipment changes, leading to increased man-hours and costs due to the complexity of forming tooth-shaped crowning on annular materials.
Innovation Solution
A crowning forming method and apparatus using a cylindrical die with first and second tooth-shaped die parts, where the first die forms a tooth shape on the outer circumference and the second die extends the central part's diameter to press the tooth shape against the inner circumference of the second die, allowing for continuous formation of tooth-shaped crowning without the need for multiple equipment changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple processes (hobbing, shaving, etc.) are combined to form tooth-shaped crowning, then manufacturing precision is improved, but device complexity and loss of time increase due to equipment changes
Solution Approach 1:
The patent combines multiple crowning formation processes into a single integrated die structure. The die includes both a first tooth-shaped die part for initial tooth formation and a second tooth-shaped die part for final crowning formation, eliminating the need for separate hobbing and shaving equipment. This merging of functions resolves the technical contradiction by maintaining high manufacturing precision through multiple forming stages while eliminating device complexity associated with equipment changes.
Solution Approach 2:
The die is segmented into distinct functional parts: a first tooth-shaped die part for forming the basic tooth shape and a second tooth-shaped die part for forming the final crowning shape. This segmentation allows each part to perform its specific function optimally within a single integrated device, resolving the contradiction by maintaining precision through specialized forming stages while avoiding the complexity of multiple separate equipment systems.
2Manufacturing precision
If multiple processes are combined to form tooth-shaped crowning, then manufacturing precision is improved, but loss of time increases due to equipment changes
Solution Approach 1:
The patent merges multiple crowning formation processes into a single die that performs both initial tooth formation and final crowning formation in one operation. This eliminates the time required for equipment changes between hobbing and shaving processes, resolving the technical contradiction by maintaining high manufacturing precision while significantly reducing loss of time associated with equipment changes.
Solution Approach 2:
The integrated die enables continuous forming action without interruption for equipment changes. The material passes through both the first and second tooth-shaped die parts in a continuous operation, maintaining manufacturing precision while eliminating downtime associated with switching between different equipment, thus resolving the time loss contradiction.
3Manufacturing precision
If multiple processes are used for crowning formation, then manufacturing precision is improved, but productivity decreases due to multiple equipment changes
Solution Approach 1:
The patent merges multiple crowning formation processes into a single integrated die structure that performs both tooth formation and crowning formation simultaneously. This resolves the productivity contradiction by maintaining high manufacturing precision through specialized die parts while eliminating the productivity loss caused by repeated equipment changes, thereby increasing overall crowning formation efficiency.
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
Enables the simple and efficient formation of tooth-shaped crowning on annular materials by reducing the need for multiple processes and equipment changes, thereby decreasing man-hours and costs while maintaining high accuracy and precision.
Implementation Method 1
a rod-like inserted part having a tip end side formed in a tapered shape may be inserted into the cylindrical mandrel, the mandrel may be configured in such a way that a diameter of a position of the mandrel that corresponds to a central part of the second tooth-shaped die part becomes larger than a diameter of each of positions of the mandrel that correspond to upper and lower end parts of the second tooth-shaped die part, and the inserted part may be pressed into a tip end side of the mandrel and the diameter of the mandrel may be extended by a tapered shape of the inserted part
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A tooth shape of the first tooth-shaped die part is formed have a constant tooth width from an upper end to a lower end and to correspond to a tooth width of a part in which a desired crowning has been produced. A tooth shape of the second tooth-shaped die part is formed to have a constant tooth width from an upper end to a lower end and to correspond to a tooth width of a central part, which is a part other than the part in which the desired crowning has been produced. A crowning forming method includes the steps of: forming a tooth shape on an outer circumference of the material by the tooth shape of the first tooth-shaped die part; and pressing the central part of the tooth shape of the material against the tooth shape of the inner circumference of the second tooth-shaped die part.