US3780413A - Method for making hollow bevel gears with integral hollow shaft - Google Patents

Method for making hollow bevel gears with integral hollow shaft Download PDF

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US3780413A
US3780413A US00283520A US3780413DA US3780413A US 3780413 A US3780413 A US 3780413A US 00283520 A US00283520 A US 00283520A US 3780413D A US3780413D A US 3780413DA US 3780413 A US3780413 A US 3780413A
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blank
bevel gear
bore
integral
die
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US00283520A
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M Burgdorf
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KM Kabelmetal AG
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KM Kabelmetal AG
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21CMANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00Extruding metal; Impact extrusion
    • B21C23/02Making uncoated products
    • B21C23/03Making uncoated products by both direct and backward extrusion
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21KMAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00Making machine elements
    • B21K1/28Making machine elements wheels; discs
    • B21K1/30Making machine elements wheels; discs with gear-teeth
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S29/00Metal working
    • Y10S29/047Extruding with other step
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49462Gear making
    • Y10T29/49467Gear shaping
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T74/00Machine element or mechanism
    • Y10T74/19Gearing
    • Y10T74/19949Teeth
    • Y10T74/19958Bevel

Definitions

  • the present invention relates to a process of making bevel gears by means of metal working.
  • the gear to be made is to have a body having configuration of a hollow truncated cone with a hollow shaft extending from the larger axial surface of the cone. More particularly, the invention relates to improvements in such processes wherein the gear is made through cold working a blank so as to obtain the desired configuration, and wherein the teeth extend from the frusto-conical body.
  • Bevel gears are used, for example, in the art of automotive engineering and here, particularly, in the gearing for the rear axle.
  • the bore through the shaft receives that axle and is usually provided with splines.
  • the intermediate product used as blank for the tooth forming process must permit filling of the bevel gear die in direction from the small diameter. Thus, this particularblank must not have a bore. If this intermediate blank has already an axial bore, the material will flow radially outwardly as the press ram or punch advances. Consequently, the blank will be deformed to have an outwardly bulging configuration resulting in an overlap at the bore during repressing the teeth. As the dimensions and tolerances of the already completed teeth must be maintained, subsequent forming steps must not move material into the region of these teeth. However, precisely that does occur when the hollow shaft portion is made through inverted extrusion whereby the teeth have to be held in a toothed die element. Therefore, it was previously necessary to make the bore subsequent to the cold working process of the gear and by means of cutting, such as drilling. Obviously, bevel gear with long shafts are very expensive to make in this manner and the process is also quite time consuming.
  • a bevel gear first through cold working, such as extrusion molding, but in solid configuration and with a solid integral shaft extending from the side with larger diameter of the gears. Subsequently, a bore is formed in the gear and shaft in that a core is extruded, beginning from the shaft end and as a direct extrusion process out of the gear through the front face of smallest diameter thereof, whereby the extruded core has slightly smaller diameter than the bore cold worked by the punch into the shaft.
  • machining is not involved to obtain the bore, nor is there the drawback resulting from using hollow blanks.
  • a die having contoured cavity corresponding to the bevel gear teeth.
  • the die has a bore beginning in the small diameter bottom of the die cavity, and having diameter smaller than the diameter of a punch acting from above for extruding a core from the bevel gear for obtaining the bore therethrough.
  • the die is provided with a conical extrusion shoulder where facing the punch. This shoulder was found to increase the life of the die, and it improves the extrusion flow conditions.
  • the FIGURE illustrates a die and punch for making a hollow bevel gear, showing the beginning of the process of bore making to the left, and showing a phase close to completion to the right of a central dividing line.
  • Blank 1 comprisesd of a body 2 of frustoconical configuration with an integral, short shaft 3.
  • Blank 1 has solid configuration and body 2 is already provided with teeth 4.
  • This blank 1 is placed into a die 5 having particularly a contour so as to matingly receive the teeth 4, crest, flank and root, in accurate contour fitting relation.
  • a sleeve 7 serving as plunge guide is placed onto the die 5 to supplement the die 5 as far as shaft 3 is concerned. The sleeve tightly receives the shaft and accordingly covers the die 5 completely.
  • the die 5 is provided with a bore 8 in the bottom and where facing the small diameter front face of the bevel gears.
  • the bore 8 has diameter smaller than an extrusion punch 6.
  • Bore 8 has a conical shoulder 10 at its upper end and is continued down in a bore 11 of somewhat larger diameter.
  • plunger or punch 6 is lowered (righthand side).
  • the punch has diameter corresponding to the diameter of the bore to be made in blank 1.
  • a core is extruded in that material in the interior of blank 1 flows out at the lower end of blank 1 and into bore 8.
  • the extruded core 9 is reduced. Core 9 is removed separately upon completion of extrusion.
  • Conical shoulder 10 improves the flow conditions from the blank into the core, and the shoulder also avoids damage to this upper edge of bore 8.
  • bore 8 has somewhat smaller diameter than punch 6, and the resulting bore in shaft and gears. This is necessary, as otherwise the material would not flow but break off. It can readily be seen that the centrally limited extrusion process does not disturb the configuration of the teeth as they have been formed previously, and the teeth are contour fittedly supported in die 5.
  • a bevel gear with integral solid shaft by means of cold working including making a frustoconical body with bevel gear teeth; and extruding from the bevel gear as a blank, a core through the small diameter surface of the bevel, through operation of a punch of larger diameter than the extruded core and acting on and through the integral shaft to obtain a bore therein.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)

Abstract

A solid bevel gear with integral solid shaft is provided as a blank and a core is extruded from this blank by means of an extrusion punch acting through the shaft end of the blank, using a die that supports the bevel gear in contour fitting relation as to the teeth and having a bore of diameter smaller than the punch through which the core is extruded. The core is subsequently removed.

Description

United States Patent 11 1 Burgdorf METHOD FOR MAKING HOLLOW BEVEL GEARS WITH INTEGRAL HOLLOW SHAFT Miirten Burgdorf, Ruckersdorf, Germany Kabel-und Metallwerke Gutehoffnungshutte Aktiengesellschaft, Hannover, Germany Filed: Aug. 24, 1972 Appl. No.: 283,520
Inventor:
Assignee:
[30] Foreign Application Priority Data Sept. 2, 1971 Germany P 21 44 006.2
US. Cl 29/1591, 29/D1G. 47, 72/358, 74/4595 Int. Cl B21d 53/28, B21h 5/00, B21k 1/30 Field of Search 1. 29/1592, 159 R, 29/D1G. 47; 72/358, 267; 74/4595 References Cited UNITED STATES PATENTS 9/1920 Paque 72/354 [4 1 Dec. 25, 1973 2,964,838 12/1960 Schober 1. 29/1592 3,298,219 1/1967 Schober 29/1592 X OTHER PUBLICATIONS Alien Property Custodian Publication, Serial No. 191, 168, Published April 27, 1943, Fritz Singer.
Primary ExaminerRichard .1. Herbst Assistant ExaminerV. A. Dipalma Att0rneyRa1f H. Siegemund [57] ABSTRACT 3 Claims, 1 Drawing Figure METHOD FOR MAKING HOLLOW BEVEL GEARS WITH INTEGRAL HOLLOW SHAFT BACKGROUND OF THE INVENTION The present invention relates to a process of making bevel gears by means of metal working. The gear to be made is to have a body having configuration of a hollow truncated cone with a hollow shaft extending from the larger axial surface of the cone. More particularly, the invention relates to improvements in such processes wherein the gear is made through cold working a blank so as to obtain the desired configuration, and wherein the teeth extend from the frusto-conical body.
Bevel gears are used, for example, in the art of automotive engineering and here, particularly, in the gearing for the rear axle. The bore through the shaft receives that axle and is usually provided with splines. In view of the rather complex configuration of such gear,
it seems obvious to make the basic body configuration first through conventional cold working, and to form the teeth separately; e.g., through press working.
Developing the latter thought further, one could, for example, start with a cylindrical blank which has been upset on one side to obtain a conical configuration. Then a bore is made through shallow forming and piercing. Finally, teeth are pressed into and from the cone. To proceed along this line means to follow the state of the art. However, bevel gears of satisfactory quality cannot be made through this application of conventional principles.
7 In order to fill completely the teeth-defining cavities in the die, the press working and extrusion process must proceed from the small diameter of the cone. Thus, upon planning production, the changes in configuration leading from the blank to the final bevel gear must not occur in an arbitrary sequence. Rather, the following rules must be observed:
The intermediate product used as blank for the tooth forming process must permit filling of the bevel gear die in direction from the small diameter. Thus, this particularblank must not have a bore. If this intermediate blank has already an axial bore, the material will flow radially outwardly as the press ram or punch advances. Consequently, the blank will be deformed to have an outwardly bulging configuration resulting in an overlap at the bore during repressing the teeth. As the dimensions and tolerances of the already completed teeth must be maintained, subsequent forming steps must not move material into the region of these teeth. However, precisely that does occur when the hollow shaft portion is made through inverted extrusion whereby the teeth have to be held in a toothed die element. Therefore, it was previously necessary to make the bore subsequent to the cold working process of the gear and by means of cutting, such as drilling. Obviously, bevel gear with long shafts are very expensive to make in this manner and the process is also quite time consuming.
DESCRIPTION OF THE INVENTION It is an object of the present invention to make hollow bevel gears with integral hollow shaft by means of a process which is more economical than the known methods as previously practiced. It is a particular object of the invention to make bevel gears with integral hollow shaft by means of cold working process that does not require machining in spite of the relatively complex configuration.
In accordance with the present invention, it is suggested to provide a bevel gear first through cold working, such as extrusion molding, but in solid configuration and with a solid integral shaft extending from the side with larger diameter of the gears. Subsequently, a bore is formed in the gear and shaft in that a core is extruded, beginning from the shaft end and as a direct extrusion process out of the gear through the front face of smallest diameter thereof, whereby the extruded core has slightly smaller diameter than the bore cold worked by the punch into the shaft. Thus, machining is not involved to obtain the bore, nor is there the drawback resulting from using hollow blanks.
For practicing the invention, a die is used having contoured cavity corresponding to the bevel gear teeth. The die has a bore beginning in the small diameter bottom of the die cavity, and having diameter smaller than the diameter of a punch acting from above for extruding a core from the bevel gear for obtaining the bore therethrough. Preferably, the die is provided with a conical extrusion shoulder where facing the punch. This shoulder was found to increase the life of the die, and it improves the extrusion flow conditions.
While the specification concludes with claims particularly pointing out and distinctly claiming the subject w matter which is regarded as the invention, it is believed that the invention, the objects and features of the invention and further objects, features and advantages thereof will be better understood from the following description taken in connection with the accompanying drawings in which:
The FIGURE illustrates a die and punch for making a hollow bevel gear, showing the beginning of the process of bore making to the left, and showing a phase close to completion to the right of a central dividing line.
DESCRIPTION OF THE DRAWING Proceeding now to the detailed description of the drawing, the left-hand position shows an intermediate product like blank 1 comprised of a body 2 of frustoconical configuration with an integral, short shaft 3. Blank 1 has solid configuration and body 2 is already provided with teeth 4.
This blank 1 is placed into a die 5 having particularly a contour so as to matingly receive the teeth 4, crest, flank and root, in accurate contour fitting relation. A sleeve 7 serving as plunge guide is placed onto the die 5 to supplement the die 5 as far as shaft 3 is concerned. The sleeve tightly receives the shaft and accordingly covers the die 5 completely.
The die 5 is provided with a bore 8 in the bottom and where facing the small diameter front face of the bevel gears. The bore 8 has diameter smaller than an extrusion punch 6. Bore 8 has a conical shoulder 10 at its upper end and is continued down in a bore 11 of somewhat larger diameter.
In operation, plunger or punch 6 is lowered (righthand side). The punch has diameter corresponding to the diameter of the bore to be made in blank 1. As the punch 6 engages the blank, and thereafter upon continued down movement of the punch, a core is extruded in that material in the interior of blank 1 flows out at the lower end of blank 1 and into bore 8. In essence,
the extruded core 9 is reduced. Core 9 is removed separately upon completion of extrusion.
Conical shoulder 10 improves the flow conditions from the blank into the core, and the shoulder also avoids damage to this upper edge of bore 8. As stated, bore 8 has somewhat smaller diameter than punch 6, and the resulting bore in shaft and gears. This is necessary, as otherwise the material would not flow but break off. It can readily be seen that the centrally limited extrusion process does not disturb the configuration of the teeth as they have been formed previously, and the teeth are contour fittedly supported in die 5.
The invention is not limited to the embodiments described above but all changes and modifications thereof not constituting departures from the spirit and scope of the invention are intended to be included.
I claim:
1. Method for making bevel gear with integral hollow shaft extending from the larger diameter surface of a frusto-conical body from which extends the teeth of the gears, comprising the steps of:
making a bevel gear with integral solid shaft by means of cold working including making a frustoconical body with bevel gear teeth; and extruding from the bevel gear as a blank, a core through the small diameter surface of the bevel, through operation of a punch of larger diameter than the extruded core and acting on and through the integral shaft to obtain a bore therein.
2. Method as in claim 1, using a supporting die having contour matching configuration for supporting the blank and having an aperture in the bottom smaller than the diameter of the extrusion plunger.
3. Method as in claim 2, using a die wherein said aperture has a bevelled shoulder.

Claims (3)

1. Method for making bevel gear with integral hollow shaft extending from the larger diameter surface of a frusto-conical body from which extends the teeth of the gears, comprising the steps of: making a bevel gear with integral solid shaft by means of cold working including making a frusto-conical body with bevel gear teeth; and extruding from the bevel gear as a blank, a core through the small diameter surface of the bevel, through operation of a punch of larger diameter than the extruded core and acting on and through the integral shaft to obtain a bore therein.
2. Method as in claim 1, using a supporting die having contour matching configuration for supporting the blank and having an aperture in the bottom smaller than the diameter of the extrusion plunger.
3. Method as in claim 2, using a die wherein said aperture has a bevelled shoulder.
US00283520A 1971-09-02 1972-08-24 Method for making hollow bevel gears with integral hollow shaft Expired - Lifetime US3780413A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE2144006A DE2144006C3 (en) 1971-09-02 1971-09-02 Process for the manufacture of bevel gears

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US3780413A true US3780413A (en) 1973-12-25

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JP (1) JPS5614379B2 (en)
BE (1) BE788203A (en)
BR (1) BR7206013D0 (en)
DE (1) DE2144006C3 (en)
FR (1) FR2150945B1 (en)
GB (1) GB1381037A (en)
IT (1) IT967093B (en)
NL (1) NL7210968A (en)
SE (1) SE380457B (en)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3895422A (en) * 1973-08-15 1975-07-22 Auto Specialties Mfg Co Screw jack pinion gear and method of making same
US4796457A (en) * 1984-07-26 1989-01-10 Daido Metal Company Ltd. Method and apparatus for producing flanged bush
US5245851A (en) * 1989-09-19 1993-09-21 M.H. Center Limited Differential pinion, metal mold for plastic working the same, and method for plastic working with the metal mold
WO1995019062A1 (en) * 1994-01-03 1995-07-13 Ateliers Thome-Genot Improved process for manufacturing alternator pole piece
US5867901A (en) * 1992-05-21 1999-02-09 Nichidai Corporation Method for producing a bevel gear shaft
FR2834763A1 (en) * 2002-01-16 2003-07-18 Mecaniques Et Ind Speciales At DIFFERENTIAL PLANETARY SPROCKET AND MANUFACTURING METHOD THEREOF
CN101780515B (en) * 2009-12-23 2012-09-05 青岛三星精锻齿轮有限公司 Process for precisely forging triple gear of dual-drive axle
CN109550802A (en) * 2018-12-14 2019-04-02 江西福格新能源传动技术有限公司 A kind of differential gear axial direction shunting cold-extrusion shaping apparatus and method

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2927192C2 (en) * 1979-07-05 1981-04-23 Kabel- und Metallwerke Gutehoffnungshütte AG, 3000 Hannover Device for the seamless production of metallic bevel gears
DE2927135B1 (en) * 1979-07-05 1980-09-11 Kabel Metallwerke Ghh Method and device for producing bevel gears
IT1283320B1 (en) * 1996-03-29 1998-04-16 Microcochlea S R L VARIABLE THICKNESS EXTRUSION METHOD AND EXTRUSION GROUP ACCORDING TO THIS METHOD
JP4154337B2 (en) * 2002-02-15 2008-09-24 古河スカイ株式会社 Impact extrusion molded article, impact extrusion molding method and impact extrusion molding apparatus
CN106040938A (en) * 2016-06-02 2016-10-26 溧阳市金昆锻压有限公司 Combined die for forging gear shaft through moulding bed and forging technology
CN112275980A (en) * 2020-10-12 2021-01-29 瑞安市亚力汽车零部件有限公司 Gear shaft precision machining method and gear shaft mold used in same

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1352911A (en) * 1919-08-01 1920-09-14 Pollak Steel Company Apparatus for forming forgings
US2964838A (en) * 1955-07-26 1960-12-20 Bluecher Wahlstatt Leichtmet Method of pressing bevel gear wheels and the like from steel
US3298219A (en) * 1963-04-24 1967-01-17 Bayerisches Leichlmetallwerk K Method and device for producing active profiles on bevel gears

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1352911A (en) * 1919-08-01 1920-09-14 Pollak Steel Company Apparatus for forming forgings
US2964838A (en) * 1955-07-26 1960-12-20 Bluecher Wahlstatt Leichtmet Method of pressing bevel gear wheels and the like from steel
US3298219A (en) * 1963-04-24 1967-01-17 Bayerisches Leichlmetallwerk K Method and device for producing active profiles on bevel gears

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
Alien Property Custodian Publication, Serial No. 191, 168, Published April 27, 1943, Fritz Singer. *

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3895422A (en) * 1973-08-15 1975-07-22 Auto Specialties Mfg Co Screw jack pinion gear and method of making same
US4796457A (en) * 1984-07-26 1989-01-10 Daido Metal Company Ltd. Method and apparatus for producing flanged bush
US5245851A (en) * 1989-09-19 1993-09-21 M.H. Center Limited Differential pinion, metal mold for plastic working the same, and method for plastic working with the metal mold
US5867901A (en) * 1992-05-21 1999-02-09 Nichidai Corporation Method for producing a bevel gear shaft
WO1995019062A1 (en) * 1994-01-03 1995-07-13 Ateliers Thome-Genot Improved process for manufacturing alternator pole piece
LT4118B (en) 1994-01-03 1997-03-25 Thome Genot Atel Improved process for manufacturing alternator pole piece
FR2834763A1 (en) * 2002-01-16 2003-07-18 Mecaniques Et Ind Speciales At DIFFERENTIAL PLANETARY SPROCKET AND MANUFACTURING METHOD THEREOF
WO2003060351A1 (en) * 2002-01-16 2003-07-24 Ateliers Mecaniques Et Industries Speciales Differential side gear and the production method thereof
US20040206151A1 (en) * 2002-01-16 2004-10-21 Guy Bostbarge Differential side gear and the production method thereof
US7093513B2 (en) * 2002-01-16 2006-08-22 Ateliers Mecaniques Et Industries Speciales Differential side gear and the production method thereof
CN101780515B (en) * 2009-12-23 2012-09-05 青岛三星精锻齿轮有限公司 Process for precisely forging triple gear of dual-drive axle
CN109550802A (en) * 2018-12-14 2019-04-02 江西福格新能源传动技术有限公司 A kind of differential gear axial direction shunting cold-extrusion shaping apparatus and method

Also Published As

Publication number Publication date
DE2144006C3 (en) 1974-03-07
FR2150945B1 (en) 1976-03-12
JPS5614379B2 (en) 1981-04-03
JPS4836056A (en) 1973-05-28
DE2144006B2 (en) 1973-08-16
BR7206013D0 (en) 1973-08-21
NL7210968A (en) 1973-03-06
IT967093B (en) 1974-02-28
SE380457B (en) 1975-11-10
DE2144006A1 (en) 1973-03-15
GB1381037A (en) 1975-01-22
FR2150945A1 (en) 1973-04-13
BE788203A (en) 1972-12-18

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