DE102007039959A1 - Cold-rolling method for lengthwise teeth and profile of long wave-like workpiece e.g. gear wheel, involves reversing round rolling tool and advancing other rolling tool for rolling other profile section - Google Patents

Abstract

The method involves performing rolling and engaging in a transition region between a rolling region (7) and a calibration region (8) of a round rolling tool (3) such that the round rolling tool is engaged separately with a freely controllable rolling carriage by oscillating circumferential movement under partial cover of teeth section until reaching a workpiece contact. The tool is reversed by making the workpiece contact to contact a workpiece (5) in the starting position of the rolling region. Other round rolling tool is advanced for rolling other profile section. An independent claim is also included for a profiling machine.

Description

The The invention relates to a method for cold rolling longitudinally Gears and profiles for long undulating workpieces with a profile rolling machine with incremental round rolling tools. The invention also relates to a profile rolling machine with incremental round rolling tools and the use of the profile rolling machine for roller compaction and temper rolling.

According to the DE 1142823 B1 is the longitudinal profiling of workpieces, especially of gears or multi-spline, associated with problems. The hot rolling of longitudinal profiles with a tool head with a plurality of symmetrically to the axis of a workpiece holder rotatably mounted profile rollers has the disadvantage that the workpieces often tend to warp even with accurate synchronism of their conical rolling surfaces abrolling and evenly driven rollers, and the Leave passage between the rollers with a curved axis or possibly also in slightly axially twisted shape. Likewise, the distortion of the workpieces during cold rolling is observed. The simultaneous action of the rollers on the entire peripheral surface of the workpiece during cold rolling leads to uncontrollable high surface pressures and bearing stresses of the rollers. The generation of precise profiles thereby requires an additional post-processing operation.

These difficulties are to be overcome in the longitudinal profiling of cold workpieces by a device corresponding to the DE 1016222 B1 a rotating rolling head with rolling rolls, which are planetary revolve around a Rollkopfachse and are profiled in a ring. The profile rollers, which are used here, are freely rotatably mounted in a motor-driven impact head, which guides the profile rollers mounted in it on a circular path during its rotation. Also from the DE 1150040 C2 It is known that in the sudden impact of each roller on the workpiece a sudden and quite considerable rotational acceleration of the individual rollers in the sense of rotation about its own axis occurs and that necessary for acceleration forces difficult to control vibrations and jerky stresses between the profile roller and the Workpiece can cause, which lead to the reduction of the surface of the profile body produced. A disadvantage is the progressive processing of the profile in the longitudinal direction, wherein an undesirable deformation of adjacent profiles can occur.

Furthermore are a variety of profile rolling machines arranged in pairs Rolling rods or round rolling tools known. These are used for production rotationally symmetrical workpieces with, for example, a straight or oblique toothing, spiral toothing, with Grooves, threads or knurling. Chipless cold rolling Profiles offers the advantage of a much faster production as the machining, being cold-rolled workpieces also a higher strength, a better surface quality and provide greater accuracy. Here are the method of cold rolling as well by the high rolling forces and the unpredictable high surface pressures and bearing stresses the rollers limits. Cold rolling of longitudinal gears and profiles in long wavy Workpieces is so far according to the width of the Rolling rod or the round rolling tool on short workpieces limited.

One problem is avoiding pitch errors when rolling gears. After CH 482487 C1 deceleration of the first half revolution of the workpiece between the brought-up toothed rollers decides the pitch accuracy for the whole further course of the deformation process. The pitch accuracy and larger material deformations in the piercing process are accomplished by incremental tools having at their periphery different Vorrollzähne same pitch and then to this in the same pitch several concentric to the axis of the role of the finished rolling teeth, wherein the profiles of the successive Vorrollzähne the profile of the Fertigigrollzähne progressively approach.

With these incremental tools, larger material deformations can be carried out than before and, in particular, gears can also be rolled. The different Vorrollzähne facilitate penetration into the workpiece. The deformation work is divided on the Vorrollzähne. Incremental tools are also the same with rack-shaped rolling tools, for example from the DE 3910003 A1 known. The CH 482487 C1 and the DE 3910003 A1 contain no indication of the cold rolling of long, wave-shaped workpieces whose longitudinal teeth or profiling extends beyond the width of the rolling rods or round rolling tools.

One Another problem with roller compaction and rolling or rolling calibration of pre-toothed gears is that when hiring the mounted in a driven roller carriage round rolling due to a different operating angle of attack profile shifts between can enter the rollers and the workpiece. This requires an exact employment and positioning of the round rolling tools at the beginning of the Anwalzvorgangs.

For example, from the DE 10031652 C1 and the DE 43 06 742 A1 Known to set the tooth pitch in the region of a Anwalzzone in the first section of the tool depending on the Vorbearbeitungsdurchmesser the workpiece to be machined. With the two point-symmetrical against the workpiece center point flat jaw tools is then once over the entire working length of the tool, starting at the most flattened tooth of the Anwalzbereiches, rolled over the lateral surface of the gear to be generated. This creates a certain basic training of future gear already in Anwalzbereich, with each tooth of Anwalzbereiches a greater penetration depth is given in the workpiece body. This method does not lead to satisfactory workpiece results with consistent quality, especially when the rolling tool with the workpiece at the beginning of the rolling process is brought into engagement with the Anwalzbereich.

The The object of the invention is a method and a profile rolling machine with the cold rolling of longitudinal gears and profiles for long wavy workpieces with round rolling tools the occurring deformation forces can be controlled safely. Another task is the avoidance of pitch errors due to material deformation in the Grooving process of the Anwalzbereiches.

According to the invention the task by a profile rolling process with a profile rolling machine with Inkrementalen round rolling tools solved by a longitudinal profiling or toothing in several rolled axially progressing sections, wherein in one first step, a first gear section with synchronous is rolled and that in a second rotary kiln and each subsequent step, a second profile section and further sections are rolled, wherein the rolling and hiring instead of in the Anwalz area in a transition area between the Anwalzbereich and the calibration range of the round rolling tools is made such that one of the round rolling tools separately with a freely controllable rolling carriage with an oscillating circumferential movement under partial overlap of the first gear section until reaching the workpiece contact is made, after which the round rolling tool with the reaching of the workpiece contact with the workpiece in the initial position of the Anwalzbereichs moved back, the second round rolling tool delivered and the rolling process of the second profile section and each other Section is made.

Of the Advantage of the threading method according to the invention only a single round rolling tool with a pendulum circumferential movement in Area of the transition section between the Anwalzabschnitt and the calibration section is based on the fact that several adjacent toothing sections with exactly the same Division and profile overlap can be rolled. By the leveling or threading of the rolling tool with respect on the already existing profiling up to the workpiece contact becomes an exact positioning of the round rolling tools to the workpiece secured. When leveling the workpiece is free to move. For this reason, during roller compaction and temper rolling pre-profiled toothings no graduation transitions or profile errors occur. The quality of the gears is increased and tool break safely avoided. It can narrow and inexpensive tools are used.

About that In addition, the stiffness of the profile rolling machine and the load the shaft bearings are lowered. Finally, that allows Process workpieces of larger dimensions produce, because the exact profiling in several sections is possible.

The Invention will be described below with reference to an embodiment explained in more detail with reference to the drawings become. Advantageous embodiments of the invention will become apparent from the dependent claims. In detail shows

1 the position of the round rolling tools in the calibration area,

2 the position of the roll in the transition area,

3 the rolling of a first toothed portion of a toothing and

4 the rolling of a second profile section of the toothing in a schematic representation.

In 1 are two parallel rolling spindles 1 a profile rolling machine for performing the method, which are driven synchronously in synchronism. The rolling spindles 1 are for example with keyways 2 provided with the help of the right round rolling tool 3 and the left hand round rolling tool 3 non-rotating and backlash-free with the rolling spindles 1 are connected. The attachment takes place at the same time with the alignment of the round rolling tools 3 in the direction of rotation 4 so that the profile tips are exactly opposite each other and the round rolling tools 3 are exactly synchronously rotationally driven. The synchronization of the round rolling tools 3 Can be guaranteed by a transfer case and drive shafts, by a common geared motor be driven. The rolling spindles 1 are stored in not shown roller carriage of the profile rolling machine, which in the feed direction in a plane to a workpiece 5 are displaceable. At the same time, the profile rolling machine has a feed control and a position control, with which the two rolling spindles 1 separately and independently of each other in the delivery direction 6 are freely positionable.

Similarly, the synchronization of the round rolling tools 3 be computer-aided over a CNC control and a central computer and control unit. The CNC control includes a CNC control software for the synchronous drive and the feed control of the rolling spindles 1 , For every rolling spindle 1 and separate drives are provided for each rolling carriage. For rolling gears, there are two independent CNC drives for the rolling spindle 1 provided that are electronically controlled by a CNC control. The CNC drive for the rolling spindle 1 includes a speed-controlled drive with a servomotor, which can be rotated by a certain angle by means of an additional position controller and a measuring system. The CNC drives enable the synchronization of the tools in 0.01 degree increments as well as stepless speed adjustment. The CNC drive motor is provided with a device that allows to determine the current rotational position of the rotor. The feedback occurs via a rotary encoder or a resolver, an incremental encoder or an absolute encoder. An electronic controller compares the encoder signal with a preset setpoint. In this way, the round rolling tools 3 exactly synchronized and independent of each other in the delivery direction 6 be positioned.

The round rolling tools 3 according to 1 have an incremental shape, in the rolling direction or direction of rotation 4 seen a Anwalzzone 7 comprising a number of Anwalzzähnen to which a calibration zone 8th connected with Kalibrierzähnen, the end or circumference by a discharge zone 9 is completed. In the run-off zone 9 the relaxing of the rolling tools takes place. Between the outlet zone 9 and the Anwalzzone 7 there is a profile recess 11 , whereby the removal of the workpiece 5 can be enabled. The Anwalzbereich 7 the round rolling tools 3 is provided with an incremental toothing, in which the tooth height from a minimum value gradually up to the height of the finished toothing of the calibration 8th increases, with the tooth root has the same height.

Between the two round rolling tools 3 is the workpiece 5 with a finished rolled toothing. 1 essentially shows the final position of the round rolling tools 3 after the rolling process in a schematic representation. The insertion of the workpiece 5 takes place after appropriate rotation of the round rolling tools 3 in the direction of rotation 4 until the initial areas of the Anwalzbereich 7 stand opposite. Here is the workpiece 5 in a workpiece holder, for example between centering tips 12 stored in 3 and 4 are shown.

In the 3 Selected representation of the round rolling tools 3 corresponds to the playback in 1 in which a workpiece 5 is produced with a longitudinal toothing. How out 3 it can be seen is the workpiece 5 a wavy workpiece 5 with a longitudinal toothing or profiling that is longer than the width of the round rolling tools 3 is. The longitudinal toothing or profiling should therefore be rolled according to the invention in several axially progressing sections.

First, in a first step, the first gear section 13 with the synchronously rotary driven rotary rolling tools 3 rolled. After the first gear section 13 is rolled, the round rolling tool 3 removed and the workpiece 5 Approved. The workpiece 5 can now by a certain amount in by the arrow 14 indicated axial direction to be moved. In this case, the axial displacement takes place by an amount which is less than the extent of the first toothed section 13 is. As a result, cover the profile tips of the round rolling tools 3 partly the already finished toothing of the first gear section 13 , For rolling the second profile section 15 and every other section, it is necessary that the teeth tips of the round rolling tools 3 during rolling exactly into the tooth grooves of the workpiece 5 intervene so that the already existing gearing is not affected.

The rolling of the second profile section 15 and each subsequent section is not in the Anwalzbereich for this reason 7 the round rolling tools 3 but in a transitional area 15 between the Anwalzbereich 7 and the calibration area 8th , The rolling is also not done simultaneously with both round rolling tools 3 but only with the right round rolling tool 3 , what in 2 is shown. The rolling is carried out in such a way that the rolling carriage with the right round rolling tool 3 gradually in delivery direction 6 to the workpiece 5 is delivered, in the embodiment, the right round rolling tool 3 a swinging circumferential movement 16 by a predetermined angle.

The leveling or threading of the round rolling tool 3 is carried out until a workpiece contact on the profile flanks of the first gear section 13 arises. The perimeter point for threading is at a point in the transition area 15 between the Anwalzbereich 7 and the calibration area 8th set to which a workpiece contact on the profile edges outside the Rohteildurchurch diameter of the workpiece 5 is available. After the workpiece contact of the first round rolling tool 3 with the workpiece 5 takes place and the full match of the first gear section 13 of the workpiece 5 with the profiling of the round rolling tool 3 is manufactured, the round rolling tool 3 with the workpiece 5 turned back and in the beginning of the Anwalzbereichs 7 hazards. In the starting position of the rolling process, the second round rolling tool 3 subsequently also sent.

Both round rolling tools 3 are exactly synchronized in synchronization. It follows that the second round rolling tool 3 with the first round rolling tool 3 also necessarily exactly to the profiling of the first gear section 13 is positioned. The rolling of the second profile section 16 and each further section takes place thereby in the exact division and mapping of the first gear section 13 , In this way, portions of a toothing can be continuously produced without the risk of missing parts.

The method is therefore also particularly suitable for roller compacting and temper rolling or smooth rolling, inter alia, from screw profiles, pump wheels and, in particular, from toothed wheels whose teeth are roll-calibrated, with particular attention to accurate positioning of the round rolling tools 3 to the already existing profiling of the gear arrives. Prerequisite for perfect results when re-rolling is the very accurate positioning of the gear between the rolling tools 3 before the round rolling tools 3 be brought into contact with the gear. The workpiece axis must be exactly parallel to the axes of rotation of the two round rolling tools 3 be aligned. This can be done in a particularly simple manner with the proposed method.

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - DE 1142823 B1 [0002]
• - DE 1016222 B1 [0003]
• - DE 1150040 C2 [0003]
• - CH 482487 C1 [0005, 0006]
• - DE 3910003 A1 [0006, 0006]
• - DE 10031652 C1 [0008]
• DE 4306742 A1 [0008]

Claims (10)

Method for cold rolling of longitudinal gears and profiles for long shaft-shaped workpieces with a profile rolling machine with incremental roll-forming tools ( 3 ), characterized in that a longitudinal profiling or toothing is rolled in a plurality of axially progressing sections, wherein in a first step, a first gear section ( 13 ) with synchronously rotary driven rotary rolling tools ( 3 ) is rolled and in a second and each subsequent step, a second profile section ( 16 ) and other sections are rolled, wherein the rolling and pitching instead of Anwalzbereich ( 7 ) in a transitional area ( 15 ) between the Anwalzbereich ( 7 ) and the calibration area ( 8th ) of the round rolling tools ( 3 ) is performed such that one of the round rolling tools ( 3 ) separately with a freely controllable roller carriage with an oscillating circumferential movement ( 16 ) with partial overlap of the first toothed section ( 13 ) until reaching the workpiece contact, after which the round rolling tool ( 3 ) with the reaching of the workpiece contact with the workpiece ( 5 ) in the initial position of the Anwalzbereichs ( 7 ), the second round rolling tool ( 3 ) and the rolling process of the second profile section ( 16 ) and every other section is made. A method according to claim 1, characterized in that the leveling off at a peripheral point of the transitional region ( 15 ) is made, on which a workpiece contact of the round rolling tool ( 3 ) on the profile flanks of the first toothed section ( 13 ) outside the blank part diameter of the workpiece ( 5 ) is available. Profile rolling machine for carrying out the method according to claim 1 to 2, characterized in that the profile rolling machine two parallel arranged rolling spindles ( 1 ), which are synchronized driven in synchronism and each with a position control and a separate control in the delivery direction ( 6 ) are freely positionable, wherein the drives of the rolling spindles ( 1 ) with the round rolling tools ( 3 ) are provided with a control with which the round rolling tools ( 3 ) a pendulum circumferential movement ( 16 ) by a specified angle. Profile rolling machine according to claim 3, characterized in that the angular amount in a transition region ( 15 ) between the Anwalzbereich ( 7 ) and the calibration area ( 8th ) is arranged. Profile rolling machine according to claim 3 to 4, characterized in that the synchronized synchronization of the round rolling tools ( 3 ) is accomplished via a transfer case and drive shafts, which are driven by a common geared motor Profile rolling machine according to claim 3 to 4, characterized in that the control for the synchronized synchronization of the round rolling tools ( 3 ) comprises a computer-aided CNC control and a central computer and control unit. Profile rolling machine according to claim 6, characterized in that separate drives are provided for each rolling carriage and the CNC control a CNC control software for the separate control of the feed movement in the delivery direction ( 6 ) of the rolling spindles ( 1 ) includes. Profile rolling machine according to claim 3 to 7, characterized in that the round rolling tools ( 3 ) have an incremental shape, which in the rolling direction a Anwalzbereich ( 7 ), a calibration range ( 8th ) and a discharge area ( 9 ) with a profile recess ( 11 ). Profile rolling machine according to claim 3 to 8, characterized in that the workpiece ( 5 ) axially displaceable with a workpiece holder, for example between centering tips ( 12 ) is stored. Use of a profile rolling machine according to claim 3 to 9 for roller compaction and subsequent rolling or smoothing under of gears, screw profiles or pump wheels.