Thin-walled hollow wheels with internal and external toothing, and apparatus and method for manufacturing the same
11498114 · 2022-11-15
Assignee
Inventors
Cpc classification
Y10T29/49462
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B21H5/02
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
In a method for manufacturing a hollow wheel which includes an internal toothing and an external toothing, wherein the internal toothing is a gear toothing, a workpiece is machined by way of a stamping tool. The workpiece has a tubular section with a longitudinal axis and a first stabilisation section for the shape stabilisation of the tubular section during the machining. The tubular section is inserted into a die having an internal die toothing. The workpiece is machined on the inner side by the stamping tool so as to simultaneously produce internal and external toothing by way of the workpiece executing a rotation movement with a temporally varying rotation speed and the stamping tool executing radially oscillating movements that are synchronised with the rotation movement.
Claims
1. A method for manufacturing a hollow wheel which comprises an internal toothing and an external toothing, wherein the internal toothing is a gear toothing, the method comprising: providing a workpiece to be machined with at least one stamping tool, wherein the workpiece comprises a tubular section with a longitudinal axis as well as at least one first stabilization section which is connected to the tubular section for shape stabilization of the tubular section during the machining with the at least one stamping tool, providing a die for receiving the tubular section, the die comprising a tubular opening in which an internal die toothing is provided, inserting the tubular section into the tubular opening, and machining the workpiece on the inner side of the tubular section inserted into the tubular opening with the at least one stamping tool to simultaneously produce the internal toothing and external toothing, wherein during the machining, the workpiece executes a rotation movement with a temporally varying rotation speed about said longitudinal axis and the at least one stamping tool executes radially oscillating movements which are synchronized with said rotation movement so that the at least one stamping tool forms the tubular section into the die toothing to produce the external toothing and to simultaneously produce the internal toothing with repeated hammering machining of the tubular section, wherein the radially oscillating movements are aligned perpendicular to the longitudinal axis.
2. The method according to claim 1, wherein a material thickness of the workpiece in the tubular section is less than twice a toothing depth of the internal toothing, before the insertion of the tubular section into the tubular opening.
3. The method according to claim 1, wherein the at least one stamping tool comprises an active region which comprises a tool head and two tool flanks adjoining the tool head.
4. The method according to claim 3, wherein the tool flanks are shaped such that the internal toothing has a longitudinal crowning.
5. The method according to claim 3, wherein the at least one stamping tool comprises two calibrating regions adjoining one of the two tool flanks each and having a shape which is a negative of a shape of a section of a tooth tip of the internal toothing.
6. The method according to claim 3, wherein the active region has a shape which is a negative of a shape of a tooth gap of the internal toothing.
7. The method according to claim 1, wherein the first stabilization section forms a non-toothed collar of the hollow wheel, said collar forming a unitary part together with the tubular section and being directed towards the longitudinal axis or away from the longitudinal axis.
8. The method according to claim 1, wherein the first stabilization section has a maximal distance to the longitudinal axis which is larger than a maximal distance the tubular section has to the longitudinal axis by at least 0.25 times a toothing depth of the internal toothing; or the first stabilization section has a minimal distance to the longitudinal axis which is smaller than a minimal distance the tubular section has to the longitudinal axis by at least 0.25 times a toothing depth of the internal toothing.
9. The method according to claim 8, wherein the first stabilization section has an outer diameter which is larger than an outer diameter of the tubular section by at least 0.5 times a toothing depth of the internal toothing; or the first stabilization section has an inner diameter which is smaller than the inner diameter of the tubular section by at least 0.5 times a toothing depth of the internal toothing.
10. The method according to claim 1, wherein the first stabilization section forms a peripheral end-face of the hollow wheel which is angled with respect to the tubular section.
11. The method according to claim 10, the first stabilization section describes an annular shape or a rotationally symmetrical truncated cone shell shape.
12. The method according to claim 1, wherein the workpiece comprises a second stabilization section and wherein at least one of the two stabilization sections is directed towards the longitudinal axis.
13. The method according to claim 1, wherein the internal toothing is designed as a full-depth toothing with a toothing depth of more than 2.0 times a normal module of the internal toothing.
14. The method according to claim 1, wherein a toothing depth of the external toothing is smaller than a toothing depth of the internal die toothing and is smaller than a toothing depth of the internal toothing.
15. The method according to claim 1, wherein the internal toothing is a spur toothing or a helical toothing or a herringbone toothing.
16. The method according to claim 1, wherein a material thickness of the workpiece in the tubular section is less than 1.5 times a toothing depth of the internal toothing, before the insertion of the tubular section into the tubular opening.
17. The method according to claim 1, wherein the internal toothing is designed as a full-depth toothing with a toothing depth of at least 2.4 times a normal module of the internal toothing.
18. A method for manufacturing a planetary gear, comprising manufacturing the hollow wheel according to the method of claim 1, and further comprising providing at least one externally toothed gearwheel and inserting of the gearwheel into the hollow wheel.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The subject-matter of the invention is hereinafter explained in more detail by way of embodiment examples and the attached drawings. There are shown schematically in:
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DETAILED DESCRIPTION OF THE INVENTION
(19) Parts that are not essential for the understanding of the invention are to some extent not represented. The described embodiment examples are exemplary for the subject matter of the invention or serve for its explanation and have no limiting effect. Most of the following embodiments, for the sake of simplicity, implicitly or explicitly relate to spur toothings but can also be conferred upon other toothing types.
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(21) The workpiece 1 has a longitudinal axis Z and a tubular section 3, which is cylindrical and is aligned coaxially to the longitudinal axis Z and into which the two mentioned toothings are incorporated by way of a stamping tool 2.
(22) The section, which is represented in
(23) The apparatus further includes a die 5, which includes an internal die toothing 5z as well as a tubular opening 5o for receiving the workpiece 1. The die 5 is held in a die holder 15, which is driveable into rotation about a rotation axis, for example, by way of a driven headstock 8
(24) The stamping tool 2, by way of which a workpiece 1 can be periodically machined, is held by way of a tool holder 12. For this, the tool holder 12 executes an oscillating movement in the radial direction (illustrated by a small double arrow in
(25) The workpiece 1 is inserted into the tubular opening 5o of the die 5 in the axial direction, as is symbolised by the open arrows, by way of the loading device 16. The tool 1 is then held in a fixed position relative to the die 5 by way of a holding device 18, which can be partly identical to the loading device 16, typically before and during the workpiece and die rotation, for example by way of pressing the two parts against one another in the axial direction.
(26) The die 5 (and in particular its die toothing 5z), the workpiece 1 (and in particular its tubular section 3 and its longitudinal axis Z) and the rotation axis of the die holder 15 are aligned coaxially to one another during the machining of the workpiece 1 by the stamping tool 2. And the workpiece 1 co-rotates with the die holder 15, for example by way of the holding device 18 being rotatably mounted.
(27) Since therefore the longitudinal axis Z of the workpiece 1 coincides with the rotation axis of the rotatable die holder 15 during the machining, for the sake of simplicity the respective axes are hereinafter both indicated as the longitudinal axis Z or as the axis Z.
(28) The die holder 15 does not need to be directly drivable for its rotation. For example, the holding device 18 can also be driven (for example directly) for rotation, and the die holder 15 is rotatably mounted and co-rotates, including the die 5 and the workpiece 1, with the holding device 18.
(29) The rotation takes place with a temporally varying rotation speed, synchronised with the radially oscillating movement of the stamping tool 2.
(30) The tool holder 12, as illustrated, can include a shank, which is driven into an oscillating movement, for producing the radially oscillating movement of the stamping tool 2. In this manner, the stamping tool 2 repeatedly, generally periodically engages with the workpiece. The workpiece 1 for its part is rotated about the axis Z with a varying rotation speed, in particular intermittently rotated (illustrated by the dashed circular arrow in
(31) Thereafter—thus in the case of intermittent rotation within the next standstill phase—the stamping tool 2 engages into the workpiece 1 again, for the further formation of the next tooth gap of the toothing to be produced, etc. The toothings are therefore produced in a cold reshaping manner by way of successively carrying out a number of stamping steps.
(32) The forces, which act upon the thin-walled workpiece 1 by way of the stamping tool 2 with the stamping reshaping, are so large that undesirable deformations of the tubular section 3 can occur without further precautions. Instead of retaining its basic circular cross section, an oval or elliptical cross section of the tubular section 3 can form and lead to an insufficient accuracy of the toothings, which is very undesirable. An undesirable conicity of the tubular section 3 can also form, so that its diameter would be increasing in a direction along the longitudinal axis.
(33) For this reason, the workpiece (during its machining) includes at least one stabilisation section. In the example of
(34) Due to their extension in the radial direction, the stabilisation sections 4, 4′ effect a shape stabilisation, so that said deformations can be prevented or at least reduced to an acceptable amount.
(35) The thin-walled workpiece 1 is formed into the die toothing 5z of the die 5 by way of the stamping tool in the described manner, for the simultaneous creation of the internal and external toothing in the tubular section 3. This is illustrated by way of
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(37) The still untoothed workpiece 1 is located in the opening 5o of the die 5 before the first stamping tool engagement (
(38) The thickly dashed line in
(39) The thin dashed lines in
(40) The stamping tool 2 includes an active region 2w, which includes a tool head 2k and two tool flanks 2f The active region 2w has a shape that is a negative of a shape of a tooth gap of the internal toothing that is to be produced (
(41) The tool flanks 2f have the shape of a negative of a flank 6f of the internal toothing 2, and the tool head 2k has the shape of a negative of a tooth root 6b of the internal toothing (
(42) Whereas the shape of the internal toothing is essentially defined by the shape of the stamping tool 2, the shape of the external toothing is defined essentially by the shape of the die toothing.
(43) The shape of a tooth tip 5a of the die toothing corresponds to a negative of the shape of a tooth root 7b of the external toothing that is to be produced. And the shape of the tooth flanks 5f of the die toothing corresponds to a negative of the shape of tooth flanks 7f of the external toothing. However, the shape of the tooth tip 7a of the external toothing is determined by free material flow. A distance remains between the tooth tips 7a of the external toothing and the respective tooth roots 5b of the die toothing. Of the tooth flanks 5f of the die toothing, it is only a section that comes into contact with the workpiece and thus determines the shape of the flanks 7f of the external toothing.
(44) A hammering forming of the first untoothed tubular section 3 into the die toothing takes place at those locations which are distributed over the periphery of the tubular section 3, at which tooth gaps of the die toothing are located, thus where the teeth of the external toothing and tooth gaps of the internal toothing come to lie (arise). For example, the workpiece 1 can be machined once in each tooth gap of the die toothing 5z by the stamping tool 2 (thus receive precisely one radially hammering impact and be reshaped by way of this), before it is machined a further time at one of the tooth gaps of the die toothing 5z.
(45) A production of the internal toothing takes place with a simultaneous production of external toothing.
(46) The number of teeth and the number of tooth gaps is identical for the internal toothing and for the external toothing and for the die toothing. And the tooth roots 6b of the internal toothing are located at the same positions along the periphery of the tubular section as the tooth tips 7a of the external toothing. And accordingly the tooth tips 6a of the internal toothing are located at the same positions along the periphery of the tubular section 3 as the tooth roots 7b of the external toothing.
(47) It is also possible to apply a second stamping tool. This, at least with regard to its active region and calibrating region, can have the same shape as the other stamping tool.
(48) The stamping tool is distanced radially from the workpiece again each between the individual hammering machining steps.
(49) In the method that is described here, no rolling of the stamping tool on the workpiece takes place, which is in contrast to some methods for profiling workpieces, termed as rolling-off. And the tool is also not permanently in contact with the workpiece but always only briefly with a subsequent phase in which no contact and no reshaping takes place. And the tool does not have a multitude of teeth that are distributed over its periphery, but, as represented, only a tooth-like active region or at the most two (not represented).
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(52) The stabilisation sections, which are shown in
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(54) However, a stabilisation section does not need to display a straight line in the represented sections, which contain the longitudinal axis Z; other shapes are also possible.
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(56) In
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(59) The typically one or two stabilisation sections are generally untoothed (toothing-free); at least they are free of the internal toothing that is to be produced and free of the external toothing that is to be produced.
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(61) In this embodiment example, with regard to which the stabilisation section 4 could otherwise also be directed inwards instead of outwards, there is a transition region 45 between the tubular section 3 and the stabilisation section 4. In the transition region there is an external residual toothing with tooth tips 45, the external residual toothing connecting to the external toothing and in which the toothing depth of the residual toothing slowly decreases, specifically from the toothing depth t7 of the external toothing to zero. An angle of the reduction of the toothing depth can be defined for example as described further above: the points, at which the residual toothing has a toothing depth of 90% of the toothing depth t7 of the external toothing or only yet 10% of the toothing depth t7 of the external toothing, in
(62) In
(63) As mentioned further above, further structures that are characteristic of the manufacturing method also form in a transition region 45 where an internal residual toothing is produced close to a stabilisation section, for example because of a stamping tool, which is longer than the length of the internal toothing is used for producing the internal and external toothing.
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(66) Since the described hollow wheels are thin-walled, these tend to be subjected to elastic deformations under loading. It is therefore appropriate to provide a longitudinal crowning of the internal toothing for a good running behaviour. Edge supports can be avoided in this manner. This can be achieved by way of a suitable design of the stamping tool 2.
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(70) In
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(73) New types of hollow wheels, components and gears can be created in the described manner, in particular ones that are suitable for lightweight construction. The respective internal cylinder toothings can be produced economically and with a high precision. The at least one collar, be it directed inwardly or outwardly, permits a shape stability during manufacture, such stability being necessary for high-precision toothings.