Toothed Part Forging with Axial Material Clearance
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Solution Overview
Problem
The existing toothed part manufacturing methods by forging result in excessive molding loads on forming dies, leading to reduced die life due to the need for high pressure to fill the die completely, which limits the precision and longevity of the manufacturing process.
Innovation Solution
A toothed part manufacturing method using a rotationally symmetrical blank with a curved outer section and axial projections, paired with a forming die featuring ring-like depressed portions, allows the material to flow in multiple directions, preventing full die filling and reducing the maximum molding load, thereby extending the life of the forming die.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the blank is compressed from the axial direction to force material radially outward to fill the forming die, then the toothed portion is formed, but the molding load increases excessively and forming die life shortens
Solution Approach 1:
The invention divides the forming die into multiple sections: a tooth profile forming portion for creating the toothed portion, and multiple material clearance portions positioned at different locations. This segmentation allows material to flow into multiple directions simultaneously, distributing the molding load across different regions and reducing peak pressure on any single area, thereby extending forming die life while maintaining toothed portion formation quality.
Solution Approach 2:
The invention introduces material clearance portions that extend in the axial direction, creating three-dimensional flow paths. Material flows not only radially outward but also axially into the clearance portions, adding a dimensional aspect to material flow that reduces resistance and molding load while ensuring complete toothed portion formation.
2Quantity of substance
If pressure is applied from the axial direction to fill the tooth profile portion, then material fills the die, but excessive load is applied to the forming die
Solution Approach 1:
The forming die is segmented into a tooth profile forming portion and multiple material clearance portions. Material flows into these clearance portions from different locations, distributing the force application across multiple entry points rather than concentrating it in a single axial direction, thereby reducing peak molding load while achieving complete material filling.
Solution Approach 2:
The material clearance portions act as intermediary regions that receive material flow from the blank. These clearance portions provide low-resistance flow paths that mediate between the applied axial pressure and the tooth profile forming portion, reducing the force required to fill the die while ensuring adequate material quantity is delivered.
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
The method reduces the molding load by allowing material flow in multiple directions, preventing excessive pressure on the forming die, which increases the die's lifespan and enables more efficient mass production of toothed parts like differential side gears at lower costs.
Implementation Method 1
applying a load in the axial direction to a radially center section of the blank such that a constituent material of the blank flows radially outward
Data Source
AI summary
When forming a toothed portion on the outer section of a blank by contacting a tooth profile-forming portion of a forming die with a curved portion of the blank, the first projection of the blank is accommodated in a first depression, and a load is applied axially to a center section of the blank so a material of the blank flows radially outward. The material of the blank at the first projection flows in the axial direction to inside the first depression, and the material of the blank at an intermediate section between the center and the outer section flows in axially to inside a second depression to form a second projection. When the load is maximized, a space is provided between a toothed portion and the tooth profile-forming portion, between the first projection and the forming die, and between the second projection and the forming die.