Toothed Part Folding and Forging for Thick Section Formation
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Solution Overview
Problem
Existing methods for manufacturing mechanical parts with significantly different target thicknesses, such as drive plates and ring gears, face challenges in securing assembling accuracy and are limited by the thickening ratio in forging, leading to potential folding failures and increased manufacturing costs.
Innovation Solution
A method involving a standing wall portion forming process through double or triple folding of a circular metal plate, followed by a tooth forming process using press forming, allows for the creation of mechanical parts with portions having thicknesses several times the initial material thickness, enabling the production of parts with distinct target thicknesses by forging a single material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickening ratio of the toothed portion is increased to secure strength, then the thickness of the toothed portion is improved, but folding failure is likely to occur in the root of the toothed portion
Solution Approach 1:
The toothed portion is divided into multiple segments along the radial direction by forming plate-like protrusions that extend in the thickness direction. This segmentation allows each segment to be independently formed with controlled thickening, preventing folding failures while achieving the required overall thickness for strength.
Solution Approach 2:
Different regions of the toothed portion are given different thickness characteristics. The plate-like protrusions create localized thickening in specific areas where strength is needed, while other regions maintain appropriate thickness to avoid folding failures. This local differentiation of quality resolves the contradiction between strength and reliability.
2Strength
If the thickness of the toothed portion is increased several times the plate thickness of the material, then the strength is improved, but the thickening ratio limitation in forging prevents achieving the target thickness
Solution Approach 1:
The invention transitions from planar thickening to three-dimensional thickening by forming plate-like protrusions that extend in the thickness direction of the material. This dimensional change allows the toothed portion to achieve several times the original plate thickness through vertical stacking of multiple plate-like structures, overcoming the traditional thickening ratio limitation of forging.
Solution Approach 2:
Multiple plate-like protrusions are nested within the toothed portion, with each protrusion containing smaller plate-like structures inside. This nested configuration enables the toothed portion to achieve significant thickness multiplication while maintaining structural integrity and avoiding folding failures.
3Adaptability or versatility
If the drive plate and ring gear are manufactured separately and then welded, then the manufacturing flexibility is improved, but the manufacturing cost increases and assembling accuracy is difficult to secure
Solution Approach 1:
The drive plate and ring gear are merged into a single integrated component by forming the ring gear structure directly on the drive plate through forging. The plate-like protrusions create the toothed portion of the ring gear while remaining integrally connected to the drive plate, eliminating the need for separate manufacturing and welding processes. This merging reduces manufacturing complexity and improves assembling accuracy while maintaining manufacturing flexibility.
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 method enables the production of mechanical parts with significantly different target thicknesses, enhancing precision, strength, and reducing manufacturing costs by maximizing the advantages of cold forging, while minimizing the risk of folding failures.
Implementation Method 1
a standing wall portion forming process in which a circular metal plate is folded to form a standing wall portion
Implementation Method 2
a tooth forming process in which press forming is applied to the standing wall portion to form teeth
Data Source
Figure 1(a)~1(d)
Figure 2(a)~2(b)
Figure 3(a)~3(b)
AI summary
A method of manufacturing a mechanical part of the present invention includes a first process of forming, by performing a folding processing to an end portion of the material, a portion to be processed having a structure, in which a plurality of layers respectively having a thickness corresponding to a plate thickness of a material overlap each other, in the material such that a plate thickness direction of the layer is orthogonal to a plate thickness direction of the material; and a second process of changing, by performing a forging processing to the portion to be processed, a shape of the portion to be processed to a target shape while press-welding the layers of the portion to be processed to each other by plastic deformation.