Frontal Toothing on Wheel Hub Inner Ring
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Solution Overview
Problem
Existing methods for forming frontal toothing on wheel hub inner rings, such as orbital forming, require complex tools and fail to ensure absolute tooth profile constancy, which is necessary for high torque transmission in modern vehicles.
Innovation Solution
A method using a single forming tool indirectly actuated to perform plastic deformation, impressing the frontal toothing onto a pre-formed upset collar with a cylindrical-symmetry creator tool, ensuring constant tooth profile accuracy through eccentric thrust and optimized stress distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If orbital forming method is used to form frontal toothing, then the toothing can be formed simultaneously with upset collar, but the tool complexity increases and tooth profile constancy cannot be ensured
Solution Approach 1:
The forming process is divided into two separate operations: first forming the upset collar, then forming the frontal toothing on the pre-formed collar. This segmentation allows each operation to use a simpler, dedicated tool rather than a complex multi-functional tool, while maintaining the benefit of integrated processing in a single setup.
Solution Approach 2:
The upset collar is formed in advance before the frontal toothing is impressed. This preliminary action creates a stable, pre-formed substrate that ensures constant tooth profile geometry during the subsequent toothing formation, eliminating the variability caused by simultaneous forming.
2Productivity
If orbital forming method is used, then the toothing can be formed, but the tooth profile dimensional accuracy and geometrical constancy are insufficient
Solution Approach 1:
The upset collar is formed in advance to provide a stable, uniformly deformed substrate. This pre-formed collar has consistent material properties and geometry, which serves as an ideal base for impressing the frontal toothing, thereby ensuring high dimensional accuracy and geometrical constancy of the tooth profile.
Solution Approach 2:
The upset collar acts as an intermediary element between the forming tool and the final toothing structure. By first creating this intermediate collar with controlled deformation, the subsequent toothing impression process achieves better precision because the collar provides a stable, uniform surface that maintains constant tooth profile geometry.
3Productivity
If complex tool is used for orbital forming, then the toothing can be formed, but the energy consumption increases
Solution Approach 1:
The forming process is segmented into two simpler operations rather than one complex simultaneous operation. Each operation uses a simpler tool with fewer moving parts and lower actuation complexity, thereby reducing the total energy consumption while maintaining the capability to form both the collar and toothing.
Solution Approach 2:
The upset collar serves as an intermediary that simplifies the overall forming process. By first creating this intermediate structure, the subsequent toothing formation requires less energy because the collar provides a pre-prepared, stable substrate that reduces the deformation resistance during toothing impression.
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 achieves higher dimensional accuracy and geometrical constancy of teeth, enabling more effective, quieter, and higher capacity torque transmissions with lower energy consumption, and can be integrated with existing orbital forming apparatus.
Implementation Method 1
a method of forming a frontal toothing on an inner ring of a wheel hub by means of plastic deformation
Data Source
AI summary
A method including the steps of forming an inner ring of a wheel hub, by joining a spindle and an insert ring fitted onto the spindle, on a side of a first end of the spindle; axially blocking the insert ring on the spindle by plastically deforming the first end of the spindle that forms an upset collar therewith, which axially protrudes from the insert ring; frontally obtaining on the collar, on the side opposite to the insert ring, a frontal toothing by means of a single creator tool, towards the collar, with a toothing complementary to that to be obtained, by axially impressing onto the collar, in sequence, one or more teeth of the complementary toothing by eccentrically pushing the creator tool against the collar while the creator tool is held substantially coaxial to the wheel hub, thus acting peripherally in sequence on the whole creator tool.