The device of wedge pressure forming process gear
Technical field
The present invention relates to a kind of device that machining is made gear that do not have, especially can processing and manufacturing tooth axle and the device of the wedge pressure forming process gear of non-complete gear wheel.
Technical background
Gear cutting process equipment of the prior art has: gear-hobbing machine, gear shapping machine, gear shaving machine, gear honing machine, gear-broach machine etc., though all be the maturation process that can effectively add work gear, but mostly be to process tooth axle and non-complete gear wheel, and metal debris arranged, the equipment of waste material.
Mill teeth method of the prior art utilizes disk-type gear milling cutter to cooperate indexing mechanism to carry out monodentate processing on milling machine.Though also can process tooth axle and non-complete gear wheel, the gained profile of tooth often has than mistake, machining accuracy is lower, and the low and cost height of production efficiency.This method only is suitable for the not high gear of jobbing work quality requirement.
" the external gear pushing and paring machine that mechanical processing technique handbook (the version 4-50 in 2007 of China Machine Press page or leaf) is recommended though can process tooth axle and non-intact gear, belongs to and bits processing is arranged and waste material, and cutter costliness and service life are short, the production cost height.
The ELEMENTARY INTRODUCTION TO NON technology of prior art gear started from for 18th century.The O.J. Bill of the U.S. in 1899 has created the technology with cold-extruded method finishing bevel gear.20 beginnings of the century, the H.N. Anderson initiative hot rolling gear of Britain.Nineteen fifty-one, the H. Ernst of the U.S. and B. lattice are spreaded out and are studied successfully cold rolling gear process.The 1950's, successful precision die forging gear is studied in the Germany.After the sixties, developed the method for powder metallurgy, power forging and fine-edge blanking gear again.At present, utilize plastic deformation of metal or the powder sintered final ELEMENTARY INTRODUCTION TO NON that is shaped of tooth-formation of gear part that makes, be divided into that cold conditions that workpiece processes at normal temperatures is shaped and workpiece be heated to hot shaping two classes of processing about 1000 ℃.The former comprises cold rolling, cold forging, stamping-out etc.; The latter comprises hot rolling, precision die forging, powder metallurgy etc.The ELEMENTARY INTRODUCTION TO NON gear can make stock utilization bring up to more than 80~95% from 40~50% of machining, productivity ratio also can be doubled and redoubled, but because of being subjected to the restriction of mould strength, generally can only process the less gear of modulus or other tooth parts, higher to required precision simultaneously gear still needs to utilize machining finishing tough profile of tooth after being shaped with ELEMENTARY INTRODUCTION TO NON.The ELEMENTARY INTRODUCTION TO NON gear need adopt special-purpose technological equipment, and initial outlay is bigger, and only (generally reaching more than ten thousand) just can reduce production costs when production lot is big.
Cold rolling gear be with gear shape roll bend pulley base radial feed, and roll mutually by certain speed ratio, make the wheel blank periphery produce plastic deformation and shut out profile of tooth.The cold rolling part of processing straight-tooth or helical gears, non-circular gear or band serration.To the gear of modulus less than 2.5 millimeters, but the bad profile of tooth that directly shuts out of trailing wheel.Modulus adopts the machining rough lumber earlier during greater than 2.5 millimeters usually, or casting, forges profile of tooth, with cold rolling the flank of tooth is made finished machined again.Be shaped owing to roll, so can't process non-intact gear.
The cold forging gear is that the mode by wheel blank plastic deformation and plastic force is different two kinds of cold-extruded and cold-headings.Cold-extruded is the generation extruding force that relatively moves of utilizing punch and die, and blank plasticity under the constraint of mould is flowed and obtains profile of tooth, is usually used in processing modulus less than 3 millimeters straight spur gear, internal gear etc.Cold-heading be utilize the hammer force of patrix make blank in mould by compression and lateral flow forms profile of tooth, be usually used in machining of bevel gears.Usually need elder generation the blank head jumping-up, and then the upsetting profile of tooth.Gear after the cold-heading has overlap, needs to cut with machining.The gear higher to required precision needs to add grinding step finishing profile of tooth one again behind the cold-forging forming.Belong to few bits processing, and can't process the tooth axle.
The stamping-out gear is to utilize the stamping die of gear shape to punch out gear from plate, is suitable for processing modulus less than 6 millimeters, thickness plate gear, tooth bar, ratchet, watch gear and the instrument gears etc. less than 10 millimeters.Can not process tooth axle and thicker non-complete gear wheel.
Hot rolling working gear principle is with cold rolling identical, but hot rolling is to carry out under workpiece is heated to thermoplastic state more than 1000 ℃.The hot rolling gear comprises operations such as preheating, rolling and shaping, and piece rate is on average less than 1 minute.To the gear that the accuracy of gear is had relatively high expectations, need reserve 0.2 millimeter allowance during hot rolling, then with gear shaving machine or gear grinding machine with worm grinding wheel finishing tooth shape.This rolling can not be processed non-intact gear, and need pay heating cost and cost of processing once more.
The precision die forging gear is that wheel blank is heated to 1000~1150 ℃, takes out to be put in the counterdie of forging hammer, forges profile of tooth for several times with the patrix hammering; Or first rough forge shaping, finish forge profile of tooth then.Produce the chance of oxide skin and improve the accuracy of gear for the wheel blank ingress of air that reduces high temperature heating in the forging process, since the seventies in 20th century, more employing high energy rate forging hammer carries out high-velocity forging, and wheel blank is shaped in thermoplasticity state hammering next time preferably.Gear behind the precision die forging needs to remove earlier overlap, is the benchmark fine finishining outside diameter of gear and other positions again with the axis hole.For the higher gear of required precision, need when die forging, reserve 0.5 millimeter allowance, so that use lathe finishing tooth shape at last.Its weak point is that operation is many and cost is very high, and is difficult to process the tooth axle.
Powder metallurgical gear is with metal dust raw material press forming in mould, then sintering is carried out in wheel blank temperature insulation with 1100~1150 ℃ in special atmosphere oven in 1.5~2.0 hours.Gear behind the sintering generally needn't or machining seldom.Though can process the gear of various profiles of tooth with powder metallurgy, the gear inside of making is contained the hole more than 5% usually, and density of material is 6.9~7.2 gram per centimeters
3, the mechanical strength of the gear of making is lower, and cost is higher.
Prior art does not have cold-rolling mill and the hot-rolling mill that machining is made gear, rolling wheel (tooth bar) in the operation of rolling, each tooth all will be subjected to the very big various external force of bending, cut, draw, press, turn round, and influences service life, improve production cost, and can not process non-intact gear.
Though above-mentioned prior art can both realize not having machining and make gear, cost is all than higher, and equipment is complicated, and mostly can not process tooth axle and non-intact gear, adopts special-purpose technological equipment initial outlay big, can not reduce production costs.
For the method and apparatus of the non-complete gear wheel flank profil of processing is a difficult problem during gear is made always.Really can efficiently not have the method equipment that machining is made non-complete gear wheel flank profil, yet there are no relevant bibliographical information so far.Though its reason is a lot, most important high efficiency, high accuracy, the processes device cheaply of still lacking.
Summary of the invention
It is little to the purpose of this invention is to provide a kind of technological equipment initial outlay, and the work efficiency height can significantly reduce production costs, and both can realize ELEMENTARY INTRODUCTION TO NON tooth axle and non-complete gear wheel, can process the device of the wedge pressure forming process gear of complete gear wheel again.
The device of a kind of wedge pressure forming process gear provided by the invention, has a drum shape casing that is shaped on pilot hole and has end cap, and the conical ring that in its pilot hole, moves up and down, be shaped on up-small and down-big internal taper hole in this conical ring, be equipped with the seat of inserting that several have the inclined-plane in the internal taper hole, the guide way that a upper and lower surface of inserting is shaped on is slidingly matched by the radially guide groove that end cap lower surface and pylon upper surface, casing bottom surface are shaped on respectively, profile of tooth is inserted around the center, and the processed tooth base workpiece face of cylinder distributes, pressurized equipment applies axial compressive force Py from top to conical ring, make the descending promotion inner cone of its conical ring inclined-plane produce radial pressure Px, the be periphery profile of tooth of tooth base workpiece axial plane of propelling is inserted and is moved along above-mentioned radially-directed groove, the toothed cutting edge that profile of tooth is inserted pushes the axial plane blank of tooth base workpiece along the contact path, make the plastic deformation of axial plane blank become the gear consistent with inlaying the module profile of tooth.
The present invention has following beneficial effect than above-mentioned prior art.
The production efficiency height.The present invention is by the drum shape casing of handling ease, embedded with conical ring simple in structure, profile of tooth with the band profile of tooth is inserted around the tooth base, radial compression tooth base material deformation becomes the technological equipment of gear, and the process-cycle is short, and initial outlay is little, production cost is low, workpiece need not to rotate and just can be shaped to gear, realizes no machining, and the several seconds gets final product gear of once-forming, the efficient height, the yield rate height.
Strength of gear teeth height after the shaping, long service life, cost is low, and material-saving.The gear error of once-forming is little, and size is accurate, the precision height, and the flank profile is bright and clean, need not the finishing profile of tooth usually.Overcome prior art powder metallurgy and processed various tooth-profile of gear, the problem that the mechanical strength that has hole to bring because of inside is low.
Worker, mould are made easily.The profile of tooth holder structure of inserting and insert is simple, be easy to make, degree of modularity height, can be easily to straight-tooth, the helical teeth standardization of various moduluses, and can use repeatedly and the life-span long.Single-piece or batch process are same to be suitable for.Workpiece and module are only born pressure, are not bent, cut, draw, turn round the influence of various external force.
The scope of application is wide.Can not only ELEMENTARY INTRODUCTION TO NON go out tooth axle and non-intact gear and complete gear wheel, but also can be assembled into the form processing of multiple shape and structure gear neatly according to dissimilar tooth form.No matter be the flank of tooth of involute, circular arc line, cycloid, the profile of tooth of commutating tooth, helical teeth, awl tooth, or non-circular gear can both be realized chipless processing.
Description of drawings
In order more to be expressly understood the present invention, now will simultaneously with reference to accompanying drawing, the present invention be described by the embodiment of the invention, wherein:
Fig. 1 is the main cutaway view of gear embedding pressure device B-B of the present invention.Zuo Bantu is the schematic diagram when exerting pressure the termination situation; Right half figure be the schematic diagram when retreating reposition and preparing the taking-up workpiece to the new workpiece situation of placement of not exerting pressure as yet or exert pressure.
Fig. 2 be the A-A of Fig. 1 to profile, represented is the situation of the non-intact gear of processing.
Fig. 3 is that the C-O of Fig. 2 is to profile.
What Fig. 4 showed is that profile of tooth is inserted under the effect of P power, the schematic diagram when tooth base embedding pressure is worked into half stroke.
Fig. 5 shows is schematic diagram when the processing termination is pressed in the embedding of workpiece tooth base.
In the accompanying drawing:
1. workpiece tooth base, 2. profile of tooth is inserted, and 2a. is fan-shaped to be inserted, 3. spring chuck, 4. the seat of inserting, the fan-shaped seat of inserting of 4a., 5. conical ring, 6. casing, 7. bolt, 8. back-moving spring, 9. end cap, 10. force-transmitting pole, 11. top, 12. gathering sills, 13. conical ring stroke rooms, 14. handling hole, 15. gathering sills, the 16. profiles of tooth front end cutting edge of inserting, Py. axial compressive force, Px. radial pressure, Ψ. cone angle.
The specific embodiment
In Fig. 1, Fig. 2, the casing of drum shape 6 is shaped on pilot hole in it.The end cap 9 that a center is shaped on handling hole 14 is housed on its top port.This handling hole 14 can be a taper hole, and it is a workpiece loading and unloading, observes operative scenario, is again to refuel, cooling, the window that clean internal is reserved.Casing 6 can just be put, inversion, side.Also be shaped on the end cap 9 and can supply 6 to 12 uniform circular holes that force-transmitting pole 10 passes.End cap 9 is fixed on casing 6 ports by bolt 7.Casing 6 bottom center are shaped on upwardly extending cylinder table, the cylinder table center have one for workpiece tooth base 1 erect top 11, its peripheral flexible anchor clamps 3.A conical ring that can move up and down 5 is arranged in the casing 6, and conical ring 5 rings inwall outer and casing 6 is slidingly matched, and is provided with cone angle Ψ in the ring and forms up-small and down-big taper hole.Workpiece to be machined tooth base 1 places on casing 6 center point 11, and by spring chuck 3 clampings, its axis overlaps with casing axes O-O, and is in plumbness.At the uniform biography column 10 of conical ring 5 upper ends annular, under the unshowned effect of top pressurized equipment, conical ring 5 is applied axial compressive force Py, make conical ring 5 descending, the conical ring stroke room 13 of the reservation of through casing 6 bottoms, the horizontal radial pressure P x that its conical ring 5 is produced by the inner cone inclined-plane passes to profile of tooth and inserts 2, toothed cutting edge 16 embeddings and extruding tooth base workpiece 1 blank surface that make profile of tooth insert 2 front ends, produce local plastic deformation, embedded part becomes tooth paddy, bump becomes tooth top, finally forms required gear.
In half figure of the right side of Fig. 1, demonstration be not exert pressure as yet or exert pressure to retreat reposition, the situation when preparing to take out workpiece tooth base 1 and placing new workpiece.Because conical ring 5 is also at highest point, the seat 4 of inserting is recessed center O, per two insert gapped between the seat 4, profile of tooth insert 2 with workpiece tooth base 1 between yet do not contact, yet gapped.For make insert seat 4 can be along with moving upward of conical ring 5 be withdrawed from squeezed state, be convenient to take out workpiece and new tooth base is installed, between seat 4 and the casing 6 back-moving spring 8 is installed inserting.
The situation in when termination of exerting pressure that shows among the Zuo Bantu, when the biography column is moved downward by axial force Py, the inner cone inclined-plane of conical ring 5 produces horizontal radial component Px, insert seat 4 and profile of tooth of promotion inserted and 2 moved towards central axis O--O direction, profile of tooth is inserted, and 2 front end cutting edge 16 embeds and extruding workpiece tooth base 1 surface, make tooth base periphery produce plastic deformation, become gear.
Its operation principle is: the conical ring 5 that is shaped on pilot hole drum shape casing 6 and moves up and down in its pilot hole, radially loading are furnished with several seats 4 of inserting that has the inclined-plane.And each seat of inserting is connected with a profile of tooth on 4 and inserts 2, be distributed on processed tooth base workpiece 1 around.The lower surface of end cap 9 is shaped on radially guide groove 15, and the middle part, bottom surface of casing 6 extends upward the pylon upper surface radially guide groove 12, constitutes to be slidingly matched with the outstanding guide way of seat 4 upper and lower surfaces of inserting respectively to move horizontally.Uniform six to 12 circular holes on the end cap 9, the force-transmitting pole 10 of pressurized equipment applies axial compressive force Py from top by this circular hole to conical ring 5, make its conical ring 5 descending promotion inner cone inclined-planes produce radial pressure Px, promote to insert and 2 move to the gathering sill horizontal direction with 4 profile of tooth that are connected of inserting, make the insert axial plane blank of 2 toothed cutting edge extruding tooth base workpiece 1 of profile of tooth, make the blank local plastic deformation, negative area becomes tooth root, bump becomes tooth top, final form and inlays the consistent gear of module 2 shapes.
Fig. 2 is the A-A profile of Fig. 1.Show be the non-intact gear of processing the time situation.The center of workpiece tooth base and the center O of casing 6 coincide, and it is 24 affixed with the seat of inserting that profile of tooth is inserted, and conical ring 5 moves up and down between seat 4 peripheries and the casing 6 inserting.When right half figure expression is not exerted pressure as yet, do not have radial load Px to occur, adjacent two profiles of tooth are inserted gapped between 2, profile of tooth insert 2 and workpiece between also gapped, be convenient to take out workpiece and new tooth base be installed.Zuo Bantu represents to exert pressure when termination, radial load Px occurred, and profile of tooth is inserted and 2 do not had the gap between 4 with inserting; The non-working position of non-intact gear, its conical ring 5 corresponding sites are not the conical surfaces, but face of cylinder 5a, and this position changes fan-shaped insert 4a and fan-shaped the insert 2a affixed with casing 6 into; When conical ring 5 moved up and down, any external force was not transmitted at this position, so this position tooth base does not produce distortion, thereby whole work-piece becomes non-complete gear wheel.
Fig. 3 is the C--O profile of Fig. 2.That its shows is the fan-shaped 2a of inserting that Fig. 2 middle and lower part accounts for whole circular 1/3rd no toothed portion, makes when the non-intact gear of processing, in order to the axial cylinder of protection workpiece tooth base 1 non-gear parts.The outer wall of the inwall of the conical ring 5 of this part and the seat 4 of inserting is the cylinder rather than the conical surface; As the square-section 5a of demonstration conical ring among Fig. 3 and the square-section 4a of the fan-shaped seat of inserting.Fan-shaped 2a and the support inserted is affixed, is fixed, does not participate in the extrusion molding of gear, and is the positioning insert of the non-machined surface of non-intact gear.
That above-mentioned Fig. 2~Fig. 3 describes is an embodiment who makes non-intact gear.Except that the non-intact gear of above-mentioned manufacturing, the present invention is equally applicable to process complete gear wheel.During the processing complete gear wheel, there is not the fan-shaped 2a of inserting, a fan-shaped 4a that inserts.It is 2 identical with the number of teeth of required gear with seat 4 the quantity of inserting that profile of tooth is inserted, and the endoporus of conical ring 5 is a complete pyramid hole or conical bores.
Fig. 4 shows when being the non-complete gear wheel of processing, and conical ring 5 strokes of exerting pressure reach the situation of a half.Profile of tooth is inserted and 2 is pushed to center O by radial load Px, and its front end cutting edge 16 existing parts embed tooth base workpiece 1, produce extruding simultaneously, force the material plastic deformation of tooth base top layer, and embedded part is becoming tooth paddy, is squeezed and bump is becoming tooth top.The profile of tooth that shows among Fig. 4 is inserted also gapped between 2, and tooth base material does not yet fill up insert space between the 2 front end cutting edges 16 of profile of tooth, exerts pressure and also should proceed.
The insert cross section geometric parameter of front end cutting edge 16 of 2 front end working faces of profile of tooth is identical with the cross section geometric parameter of a tooth paddy of required gear.Insert 2 by the profile of tooth of changing various geometric, just can process different gears.Its tooth curve can be involute, circular arc line, cycloid; Tooth surface shape can be spur gear, helical gear, bevel gear.
When processing non-complete gear wheel, insert 2 quantity of profile of tooth Duos 1 than the number of teeth of required gear, and identical with the tooth paddy quantity of required gear; Processing is during complete gear wheel, and profile of tooth is inserted, and then the number of teeth with required gear is identical for 2 quantity.
From the motive power of pressurized equipment, can be hydraulic coupling, atmospheric pressure, mechanical force or the electric power that this equipment provides.
Fig. 5 shows is situation when exerting pressure termination.Radial pressure Px acts on profile of tooth and inserts 2, and inserting up to each profile of tooth just stops when gap between 2 is zero.Make tooth base workpiece 1 surface produce local plastic deformation, form ditch shape tooth paddy and strip tooth top gradually, tooth base workpiece 1 is deformed into non-complete gear wheel.When external force Py pulling conical ring 5 moved upward, the seat 4 of inserting deviated from the center at the thrust lower edge of back-moving spring 8 horizontal line and moves, and the space occurs, takes out the gear workpiece, the process-cycle of finishing a gear.
Principle of the present invention is: the profile of tooth identical with the number of teeth of required gear inserts 2, is periphery around tooth base workpiece 1 to be processed, can move back and forth along the radially guide groove of setting, when it is subjected to the time spent of doing of external force Px, a plurality of profiles of tooth insert 2 simultaneously synchronous coordinations do entad motion.As a result, insert 2 front end cutting edge 16 of profile of tooth forces the top layer material plastic deformation of tooth base workpiece 1, and the cutting edge embedded part becomes tooth paddy, is squeezed and bump becomes tooth top, obtains required gear.