Toothed Part Manufacturing Reducing Molding Load
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Solution Overview
Problem
The existing toothed part manufacturing methods using forging techniques require high molding loads, which shorten the life of the forming die due to excessive pressure, leading to variations in product dimensions and precision.
Innovation Solution
A toothed part manufacturing method that applies a load in the axial direction to a cylindrical blank while constraining its outer surface, allowing the material to flow radially outward and axially toward a depressed portion of the forming die, creating spaces between the blank and die to reduce the 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 the forming die life shortens
Solution Approach 1:
The patent introduces a depressed portion in the forming die that causes material to flow not only radially outward but also axially into the depression. This multi-directional flow path reduces the peak molding load by distributing the material flow across different spatial dimensions, thereby forming the toothed portion while extending forming die life.
2Manufacturing precision
If further pressure is applied from the axial direction after filling the tooth profile portion, then the toothed portion is completed, but the molding load increases and forming die life shortens
Solution Approach 1:
The depressed portion is designed with specific dimensions that allow partial filling - the material flows into the depression but does not completely fill it. This partial action approach ensures the toothed portion is properly formed while avoiding the excessive material flow that would require prohibitively high molding loads.
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 reduces the molding load, preventing excessive pressure on the forming die, increasing its lifespan and maintaining product precision, allowing for mass production of toothed parts like differential pinion gears at lower costs.
Implementation Method 1
a constituent material of the blank flows radially outward, the constituent material of the blank at an intermediate section between the center section and the outer section flows in the axial direction toward a depressed portion of the forming die to form a projection portion
Data Source
AI summary
A method for manufacturing a toothed part from a cylindrical blank using a forming die. When forming a toothed portion on a radially outer section of the blank by applying a load in the axial direction of the blank to a radially center section of the blank while constraining a portion of an outer circumferential surface of the blank such that a constituent material of the blank flows radially outward, the constituent material of the blank at an intermediate section between the center section and the outer section flows in the axial direction toward a depressed portion of the forming die to form a projection portion. When the load is at maximum, a space is provided between the toothed portion and the forming die, and a space is provided between the projection portion and the forming die.