A multi-station, reciprocating die pattern forming machine (500), including a pair of parallel reciprocal slide members (502, 503) with spaced pairs of pattern forming dies (504) thereon reciprocal between an insert position and an eject position. Drive mechanism (505, 506, 510) reciprocates the die pairs alternately between the insert position and eject position. Mechanism delivers and positions a pattern receiving blank (600) to a pair of dies when in the insert position. Axial translation of the dies causes the dies to rotate the blank at a center of process and impart a pattern upon the blank. Servo-motors on blank positioning mechanism provide feedback recognition of the position of the blanks during processing. The invention also relates to a method of patterning blanks.

A tool manufacturing method includes the steps of preparing a cylindrical blank, dividing the blank into sections, changing an outer diameter of one of the sections, and shaping the sections to complete a tool. During the shaping step, the section whose outer diameter is changed is shaped into a symmetrical polygon for serving as a head portion of the tool and shaping another section to obtain a polygon with alternate concavities and convexities thereon for serving as an engaging portion of the tool. Accordingly, the progressive execution of the method prevents the deterioration of the blank made of a high carbon content metal material, allows the tool to keep good mechanical properties, increases the manufacturing efficiency, and reduces manufacturing costs.

A rolling tool (5) has a basic body (6) for fastening the rolling tool (5) in a rolling machine (1) and a profiled part (7) for the shaping treatment of a workpiece (2) to be rolled. The basic body (6) and the profiled part (7) are of multi-piece design. The basic body (6) and the profiled part (7), in their interconnected position, are mounted movably relative to one another in a plane perpendicular to the rolling direction (23). The basic body (6) of the rolling tool (5) can also be part of the rolling machine (1).

A method for manufacturing a gear which effectively prevent a crack from occurring inside a tooth part when rolling processing is performed on a teeth part of a gear raw material is achieved. A method according to one embodiment for manufacturing a gear by performing rolling processing on a tooth part of a sintered gear raw material. The method includes, when the rolling processing is performed on the tooth part of the gear raw material, pressing the gear raw material toward a center of rotation of the gear raw material by a rolling machine and, when at least the rolling processing is performed on the tooth part of the gear raw material toward a center of a thickness thereof by a pressing machine, pressing a region where an internal density of the tooth part of the gear raw material decreases.

A gear manufacturing method includes a step of preparing a gear blank; a step (teeth cutting step) of cutting the gear blank to form a half-finished gear having a plurality of gear teeth; a step (heat treatment step) of heat-treating the half-finished gear having the gear teeth; and a step (form rolling step) of rolling the half-finished gear which is subjected to the heat treatment, in which the gear teeth of the half-finished gear which is subjected to the teeth cutting step is formed with protuberances on both sides in a circumferential direction, and at the form rolling step, the protuberances are pressed by a rolling die, so that the half-finished gear becomes a gear.

A planet (11) for a planetary rolling contact gear, along whose planetary axis a middle section (12) having a larger diameter and, axially on both sides of the middle section (12), end sections (13) having a smaller diameter are formed, wherein a first engagement profile (14) is formed on the lateral surface of the planet (11) in the middle section (12) and a second engagement profile (15) is formed on the lateral surface of the planet (11) in the end sections (13), wherein the first engagement profile (14) has a plurality of first teeth (16) that are arranged in an annular manner around the planetary axis, wherein first grooves (17) arranged in an annular manner about the planet axis are formed between successive first teeth (16), wherein the two first edge teeth (23) located at the ends of the middle section (12) are formed within and at a distance from a tooth contour (18) of the first teeth (16) of the middle section (12).

A multi-station, reciprocating die pattern forming machine (500), including a pair of parallel reciprocal slide members (502, 503) with spaced pairs of pattern forming dies (504) thereon reciprocal between an insert position and an eject position. Drive mechanism (505, 506, 510) reciprocates the die pairs alternately between the insert position and eject position. Mechanism delivers and positions a pattern receiving blank (600) to a pair of dies when in the insert position. Axial translation of the dies causes the dies to rotate the blank at a center of process and impart a pattern upon the blank. Servo-motors on blank positioning mechanism provide feedback recognition of the position of the blanks during processing. The invention also relates to a method of patterning blanks.

A thread-rolling flat die for a threaded fastener, includes a thread-rolling surface including at least a bite surface to which a workpiece of the threaded fastener is supplied, a finishing surface formed adjacent to the bite surface, and a roll-off surface formed adjacent to the finishing surface. The bite surface includes at least: a first partial bite surface having an inclination and a second partial bite surface formed continuously from the first partial bite surface and having an inclination. A length L1 along a thread-rolling direction in the first partial bite surface, a length L3 along the thread-rolling direction in the finishing surface, a length L4 along the thread-rolling direction in the roll-off surface, and a diameter of a processed portion of the workpiece of the threaded fastener have a relationship of L1>L3>L4> the diameter of the processed portion.

A reciprocating die roll forming machine for forming a pattern such as a thread form on the outer surface of a cylindrical blank includes at least one set of reciprocating dies operating upon the blank which rotates in place. The machine includes a slide and bearing combination to support the dies belt driven by a servo-motor controlled by a central processing unit. Mechanism is provided to deliver and position a blank for engagement by the dies. In one form, the machine includes multiple die sets to produce multiple parts during one die reciprocation cycle. In another form, the machine employs separate drive mechanisms to independently drive each die of a set.

[Problem to be Solved] A thread-rolling flat die for a threaded fastener capable of long life and a thread-rolling method using the thread-rolling flat die for a threaded fastener are provided.

[Means for Solving the Problem] A thread-rolling flat die 1 is provided with a first partial bite surface 15 having an inclination with an angle with respect to a finishing surface 13, and a second partial bite surface 16 formed between the first partial bite surface 15 and the finishing surface 13 and having an inclination with an angle with respect to the finishing surface 13. A crest angle 1 of a processing tooth 31 at a thread-rolling starting point 17 in the first partial bite surface 15 is larger than a crest angle 2 of a processing tooth 31 in the finishing surface 13. Therefore, loads applied to dies 10, 50 can be reduced, and this allows a longer life of the thread-rolling flat die 1.