DE102008045728C5 - rolling bar - Google Patents

Abstract

Roll bar (1a, b) with a working direction (10) applied profiling, in particular toothing (2), for producing a toothing (21) on the circumference of an associated, in particular rotatable, workpiece (20), characterized in that the over Width (9) of the toothing (2) integral rolling rod (1a, b) in the working direction (10) after the manufacturing area (3), which comprises at least one calibration (5), a phase region (7) for chamfering the beginning (21a) Has toothing (21) of the workpiece (20).

Description

field of use

The invention relates to a rolling rod according to the preamble of patent claim 1 and a method for producing a toothing according to the preamble of patent claim 14.

Technical background

Circumferential profiles, in particular toothings, such as straight or oblique splines, but also oil grooves, threads or knurls, are meanwhile almost always manufactured by chipless cold forming because of the significantly higher production speed compared to the machining.

For this purpose, the workpiece rolls with its circumference on the correspondingly profiled work surface, usually a rod-shaped forming tool, the so-called rolling rod, so that the profiling of the rolling rod due to the applied pressure between the workpiece and tool on the circumference of the rule rotationally symmetrical workpiece images.

To improve the workpiece support of the work result and acceleration of the operation, the workpiece rolls simultaneously on two opposite sides on two opposing analog rolling rods by being rotatably received stationary in a tooling machine, while the two rolling rods tangentially to the rotating workpiece be moved in pressing directions in opposite directions.

As a rule, the profiling to be produced on the workpiece is completed by only one traverse of the rolling rod and the rolling rod is then lifted off the workpiece.

If the control of the transverse distance between the rolling rod and the workpiece during machining is fast enough and accurate enough, profilings on non-round, for example elliptical, workpieces can be produced in this way.

One problem in this case is the chamfer areas, which are particularly desirable in the case of splines, at the beginning on one side of the teeth on the workpiece, which considerably facilitates the insertion of the corresponding counter element into the spline, so that the automation of this splicing operation is possible.

This has been solved by the Anfasbereich the produced toothing on the one hand and the adjoining normal range of teeth to be produced on the other hand either in two separate steps and of course with separate tools were made, or in a single step, but also by means of two separate, juxtaposed rolling rods each side of the workpiece, one of which generates the Anfasbereich and the other the normal range of the toothing to be produced.

• - Einlaufbereich, in dem die Profilierungen in der Walzstange in Arbeitsrichtung zunehmend immer tiefer werden und sich der endgültigen Zahnform annähern,
• - einen Kalibrierbereich, in dem die endgültige Profilierungsform wiederholt und auf dem Werkstück fixiert wird und
• - einem Entspannungsbereich, in dem die Profilierungen auf der Walzstange wieder geringfügig niedriger und kleiner werden und dadurch eine Entspannung der während des Umform- und Kalibrierbereiches sehr hohen inneren Spannungen in der Maschine ermöglichen noch vor dem Abheben des Werkzeuges vom Werkstück. Dadurch wird ein Abheben des Werkzeuges überhaupt erst möglich.

This means a high manufacturing outlay for the production of four instead of two rolling rods, each having in their longitudinal direction, ie the working direction, consecutively different areas and thus differently shaped profiles. In general, the rolling rods are divided into the

• Inlet area in which the profilings in the rolling bar in working direction increasingly become deeper and closer to the final tooth shape,
• a calibration area in which the final profiling shape is repeated and fixed on the workpiece and
• - A relaxation area in which the profiles on the roll bar again slightly lower and smaller and thereby allow relaxation of the during the forming and Kalibrierbereiches very high internal stresses in the machine before lifting the tool from the workpiece. As a result, a lifting of the tool is possible in the first place.

However, due to the manufacturing process of the rolling rods by grinding by means of correspondingly profiled grinding wheels, which are guided transversely to the working direction on the rolling rods, forming both the normal range of the teeth and the Anfasbereiches side by side on one and the same roll bar was not possible.

However, the two separate and in the rolling machine next to each other - without distance - fixed rods for the two areas are always a problem, because even so small, heels between the rods the flow of the material of the teeth on the workpiece obstructed and in addition a albeit very small Paragraph between the two rolling rods can be visible and felt later on the workpiece and there also z. B. complicate the postponement and mounting a counter element.

Especially with increasing wear of the rolling rods wear will increase in the joint between the rolling rods of the first and so that the corresponding paragraph on the workpiece are the first larger.

In the case of juxtaposed rolling rods for normal toothing and Anfasbereich there is the additional disadvantage that when adjusting the diameter of the workpiece, so radial delivery of the rolling rods in the direction of the workpiece center, automatically in the same way the Anfasbereich is affected, and not adjusted separately can.

Furthermore, it is from the DE 43 06 742 A1 as next reaching, both for the rolling rods and the manufacturing process generic type, Scripture known that generic rolling rods successively have an area for pre-profiling and one for the calibration. However, a phase range is not disclosed there. About the same scope of disclosure has the DE 10 2004 035 153 A1 ,

Furthermore, it is known from DE 51257 from 1889 for thread rolling on screws, that the corresponding rolling rods in the longitudinal direction one behind the other have areas for producing different profiles, but not for producing a phase.

However, the different profilings produced are located axially next to each other on the workpiece.

Furthermore, it should be remembered that during thread rolling, the material flows in the production of the thread in the axial direction, while in the manufacture of gears the material flows only in the radial direction and slightly in the circumferential direction, but a flow in the axial direction is just to be avoided ,

Presentation of the invention

Technical task

It is therefore the object of the invention to provide a rolling method and a corresponding tool, which also enables a Anfasbereich on the profiling to be produced, in particular toothing of the workpiece in one operation and without the described disadvantages of the prior art.

Solution of the task

This object is solved by the features of claim 1. Advantageous embodiments will be apparent from the dependent claims.

The procedure according to the invention consists in first producing the profiling on the workpiece over its entire width, that is to say at least partly also in the later chamfering area, and then subsequently further shaping the chamfered area of the normally shaped teeth produced there into the chamfered form.

This can be carried out in particular in one work step, above all by providing a relaxation phase for the workpiece after the normal profiling has been produced without the chamfering area, before the forming of the teeth takes place in the chamfering area.

This offers the advantage that after generating the normal profiling without the Anfasbereich where appropriate, the tool can be delivered radially with respect to the workpiece, which is not a problem in the CNC machines commonly used as a production machine. In particular, when a relaxation phase is provided, this period can be used for automatically changing the positioning of the tool, so the rolling rod.

Thus, the normal gear area and the chamfer area can be set independently, which is often necessary especially for workpieces with different material properties, depending on the batch used.

This is made possible with a rolling rod as a tool, in which in the working direction, ie the longitudinal extent of the rolling rod, after the production range for the normal toothing shape over the entire width, but without the chamfer, followed by a phase range.

By means of this phase region, the beginning of the teeth already produced in the production area is reshaped on the workpiece, in which it is equipped with a chamfering area.

It is so material from the already generated normal beginning of the teeth so shifted that there the desired chamfer arises.

For this purpose, the teeth of the phase range of the tool are within the width of the toothing of the manufacturing area, but can also go beyond the width, especially if the profiling to be produced on the workpiece is at the end of a workpiece, such as a shaft.

The production area on the rolling rod for the production of the normal workpiece profiling without chamfering can as usual a Calibration area and also include an upstream inlet area.

Whether there is also a relaxation area between the phase area and the calibration area often depends on the material of the workpiece, the thickness of the chamfer and other concrete individual case parameters.

The more accurate the chamfer must be made, the more recommendable is the provision of a relaxation area, since reshaping from the already relaxed state of the machine results in more accurate end results than the reverse case when the machine is decompressed only after chamfering and then the final dimension changed more.

The teeth in the phase region of the rolling rod can either have the same cross-section as the teeth in the production area, in particular in the calibration area, and in contrast - viewed in the working direction - be merely inclined to produce the desired chamfer angle.

Depending on the material of the work piece and design of the joint connection, this chamfer angle should be between 1 ° and 15 °, better between 1.5 ° and 10 °, better between 2 ° and 5 °, because there is a danger, especially if the chamfer angle is too large in that the material which has to be displaced out of the normally preformed teeth is not displaced in the direction of the tooth end, but during chamfering back into the direction of the normal toothing on the workpiece and there generates irregularities in the tooth form.

In order to achieve a clean transition between chamfering region and normal region on the workpiece, the teeth of the phase region may extend over more than just the width of the chamfering region on the workpiece, especially on the normal toothing side.

Whether an extension beyond the Anfasbereich out in the other direction, ie beyond the end of the teeth, is possible depends on whether the toothing is at the end of a workpiece, or in the central region, then in the toothed Area a mostly smooth peripheral surface connects, in which the extended teeth of the rolling rod should not penetrate.

However, if the chamfering area is at the end of the workpiece, then the teeth of the phase region of the rolling rod can reach beyond the end of the workpiece, but also at the level, ie the radial extent with respect to the workpiece center, to a height below the tooth base Teeth extend in the normal range of the workpiece.

In difficult to be formed materials, it may be useful that the teeth of Anfasbereiches on the rolling rod not all have the same shape, but in the working direction, for example, have an increasing height.

For the same reason, it may also be expedient that the teeth in the chamfering region of the rolling rod also have a changing cross section in their course direction, ie transversely to the working direction of the rolling rod.

The goal in both cases is such a design that when chamfering a flow direction of the material of the normal preformed ends of the teeth on the workpiece towards the front end of the teeth is achieved and no backflow of material into the normal axial region of the teeth takes place.

list of figures

• 1: eine Walzstange nach dem Stand der Technik,
• 2: eine erfindungsgemäße Walzstange,
• 3: Aufsichten auf eine erfindungsgemäße Walzstange in Prinzipdarstellung,
• 4: eine Darstellung der Arbeitssituation am Werkstück beim Anfasen, und
• 5: die Grundsituation beim Flachbacken.

Embodiments according to the invention will be described in more detail below by way of example. Show it:

• 1 : a rolling bar according to the prior art,
• 2 a rolling rod according to the invention,
• 3 : Plan views of a rolling rod according to the invention in schematic representation,
• 4 : a representation of the work situation on the workpiece during chamfering, and
• 5 : the basic situation when baking flat.

1 shows a rolling rod 1a in the side view as well as in the front view as in the in 5 illustrated basic situation during cold rolling is used.

This is the workpiece 20 fixed on two opposite sides, rotatably supported and driven or not driven and in this case up and down and one rolling rod 1a . b with the side of their gearing 2 tangential to the circumference of the workpiece 20 hung up. The two rolling rods 1a . b become in their opposing directions 10 synchronously move against each other, reducing their gearing 2 on the circumference of the workpiece 20 unroll and by the radial pressure of the rolling rods 1a . b against the workpiece 20 whose teeth 2 on the circumference of the workpiece 20 memorize.

• Den größten Teil der Länge der Verzahnung 2 nimmt der Einlaufbereich 4 ein, in dem die Höhe und gegebenenfalls auch der Querschnitt der Zähne 12 in Arbeitsrichtung 10 zunimmt, so dass sich immer tiefere Abdrücke in dem Umfang des Werkstückes 20 abdrücken.

For this purpose, the in 1a Roll bar shown individually in the side view 1a of the prior art on its upper side a toothing 2 that are in working direction 10 - in the labor input the workpiece 20 along the rolling rod 1a moved - has several areas:

• Most of the length of the gearing 2 takes the inlet area 4 a, in which the height and possibly also the cross section of the teeth 12 in working direction 10 increases, so that ever deeper impressions in the circumference of the workpiece 20 pull the trigger.

Accordingly, the workspace 4 significantly longer, especially a multiple as long as the circumference of the workpiece to be profiled 20 ,

At the end of the inlet area 4 follows the calibration range 5 in which the teeth 12 - only in the calibration area 5 of the 1a as individual teeth 12 are shown, in reality, of course, over the entire length of the teeth of the rolling rod 1a are present - the corrected to the elastic part of the deformation negative mold of the toothing to be produced 21 on the workpiece 20 have.

This calibration range 5 has a length that is at least the simple circumference of the workpiece to be machined 20 must correspond.

In working direction 10 joins in a relaxation area 6 in which the teeth 12 Although it may have a constant height, but the tooth base of the teeth 2 on the rolling rod 1a approaches the bottom of the rolling rod and thereby the radial pressure against the workpiece 20 with increasing movement of the workpiece 20 along the relaxation area 6 is reduced.

The front view of the 1b shows that the rolling rod is formed in two parts, namely across the width 9 the gearing 2 through two adjacent rolling rods 1a and 1'a ,

It is by means of the rolling rod 1a the normal range of toothing 21 on the workpiece 20 manufactured, in which the course direction 14 the teeth 2 , especially the tips of the teeth 2 parallel to the axial direction 11 of the workpiece 20 runs while with the rolling rod 1'a the chamfer area 23 the workpiece toothing 21 should be made, which is why the teeth 2 this rolling rod 1'a in their working direction 10 , ie the line of sight of the 1b , considered course direction 14 slightly inclined to the direction of the teeth 2 the rolling rod 1a run.

Both the rolling rod 1a as well as the rolling rod 1'a each have the basis of the 1a illustrated sequence of inlet area 4 , Calibration range 5 and relaxation area 6 ,

• Wie die Querschnitte an den Stellen B und C in den 2b und 2c zeigen, erstreckt sich die Breite 9 der auf der einstückigen Walzstange 1a aufgebrachten Verzahnung 2 im Wesentlichen über die gesamte Breite der herzustellenden Werkstück-Verzahnung 21.

2 on the other hand shows the rolling rod according to the invention:

• Like the cross sections in the places B and C in the 2 B and 2c show, the width extends 9 the on the one-piece rolling rod 1a applied toothing 2 essentially over the entire width of the workpiece toothing to be produced 21 ,

A chamfering area 23 the workpiece toothing 21 - as best in 4 to recognize - is produced by the fact that a corresponding phase range 7 on the gearing 2 the rolling rod 1a in working direction 10 behind the manufacturing area 3 located, and the workpiece toothing 21 initially without Anfasbereich 23 through the manufacturing area 3 will be produced.

Accordingly, the manufacturing area 3 the rolling rod 1a in working direction 10 one after the other usually an inlet area 4 and a calibration area 5 on, in which the course direction 14 the teeth 12 parallel to the bottom of the rolling rod 1a and thus to the axial direction 11 of the workpiece 20 runs.

To the manufacturing area 3 closes in working direction 10 the phase range 7 in which the course direction 14 ' the teeth 12 one - in 4b greatly exaggerated - phase angle 13 slightly inclined to the course direction 14 the teeth 12 runs in the manufacturing area, according to the desired chamfer in Anfasbereich 23 the workpiece toothing 21 ,

• Wie die Arbeitssituation der 4 zeigt, kann bei einer Verzahnung 21, deren Anfasbereich 23 sich am unmittelbaren Ende des Werkstückes 20 befindet, sich die Verzahnung 2 der Walzstange 1a, b, vor allem in deren Phasenbereich 7, sich axial über das Ende des Werkstückes 20 hinaus erstrecken und sich dadurch auch unterhalb des Niveaus des Kerndurchmessers des verzahnten Werkstückes 20 sich heraberstrecken, was bei einer Verzahnung im axialen mittleren Bereich eines Werkstückes nicht möglich wäre.

Whether it is the tooth tip of the Werkzeugzverzahnung 2 at the highest point of the phase range 7 equal to or higher than the tooth tip in the manufacturing area 3 , depends primarily on whether the gearing to be produced 21 at an axial end of the workpiece 20 or in its middle area:

• How the work situation of 4 shows, can be at a gearing 21 , their Anfasbereich 23 at the immediate end of the workpiece 20 is located, the gearing 2 the rolling rod 1a . b , especially in their phase range 7 , axially over the end of the workpiece 20 extend and thereby also below the level of the core diameter of the toothed workpiece 20 diverge, which would not be possible with a toothing in the axial central region of a workpiece.

Further shows 3 in views of rolling rods according to the invention 1a - Only in schematic representation - that is a relaxation area 6 still within the manufacturing area 3 for making the teeth 21 without chamfering, ie after the calibration range 5 , or at the end of the rack 1a , ie at the end of the phase range 7 What mainly of the material of the workpiece to be machined 20 and depends on the prevailing pressure conditions during processing.

3a also shows with dashed lines in the phase domain 7 that the teeth 12 in the direction of the chastised beginning 21a the toothing to be produced 21 continue in the axial direction, ie transversely to the working direction 10 , can protrude as in the manufacturing area 3 , so that by the manufacturing area 3 produced, not chamfered beginning 22a a tooth 22 on the workpiece 20 then by means of the axially further projecting phase range 7 not only is depressed, but the material of the beginning 22a of the tooth 22 axially further forward in the direction of the tooth 22 is relocated.

LIST OF REFERENCE NUMBERS

1a, b

Walzstange

2

Walzstangen-Verzahnung

2.3.

Zähne in Herstellbereich

2.7.

Zähne im Phasenbereich

3

Herstellbereich

4

Einlaufbereich

5

Kalibrierbereich

6

Entspannungsbereich

7

Phasenbereich

9

Breite

10

Arbeitsrichtung

11

axiale Richtung

12

Zahn

13

Fasenwinkel

14, 14'

Verlaufsrichtung

14.3.

Verlaufsrichtung der Zähne im Phasenbereich

14.7.

Verlaufsrichtung der Zähne im Herstellbereich

20

Werkstück

21

Werkstück-Verzahnung

21'

Verzahnung ohne Anfasung

21a

Anfang

22

Zahn

22'

Zahn ohne Anfasung

22a

Anfang

23

Anfasbereich

(Phase = tool side,
Chamfer = workpiece side)

1a, b

rolling bar

2

Rolling racks gearing

2.3.

Teeth in manufacturing area

2.7.

Teeth in the phase area

3

manufacturing area

4

intake area

5

calibration

6

relaxation area

7

phase range

9

width

10

working direction

11

axial direction

12

tooth

13

bevel angle

14, 14 '

running direction

14.3.

Direction of the teeth in the phase range

14.7.

Course of the teeth in the manufacturing area

20

workpiece

21

Workpiece toothing

21 '

Gearing without chamfering

21a

Beginning

22

tooth

22 '

Tooth without chamfering

22a

Beginning

23

Anfasbereich

Claims (17)

Roll bar (1a, b) with a working direction (10) applied profiling, in particular toothing (2), for producing a toothing (21) on the circumference of an associated, in particular rotatable, workpiece (20), characterized in that the over Width (9) of the toothing (2) integral rolling rod (1a, b) in the working direction (10) after the manufacturing area (3), which comprises at least one calibration (5), a phase region (7) for chamfering the beginning (21a) Has toothing (21) of the workpiece (20). Roll bar (1a, b) after Claim 1 , characterized in that the production area (3) also comprises a relaxation area (6). Roll bar (1a, b) according to one of the preceding claims, characterized in that the production area (3) also comprises an inlet area (4). Roll bar (1a, b) according to one of the preceding Claims 2 or 3 , characterized in that the relaxation area (6) has a length of at least half, better ¾, the length of the circumference of the workpiece (20). Roll bar (1a, b) according to one of the preceding claims, characterized in that viewed in the working direction (10), the course direction (14.7) of the teeth (2.7) of the phase region (7) by a chamfer angle (13) relative to the direction (14.3) Teeth (2.3) of the manufacturing area (3) inclined. Roll bar (1a, b) after Claim 5 , characterized in that the chamfer angle (13) is a maximum of 15 °, better at most 10 °, better at most 5 °. Roll bar (1a, b) according to one of the preceding Claims 5 or 6 , characterized in that the chamfer angle (13) is at least 1 °, better at least 1.5 °, better at least 2 °. Roll bar (1a, b) according to one of the preceding Claims 5 to 7 , characterized in that the cross-sectional shape of the teeth (2.7) of the Phase range (7) is the same as that of the teeth (2.3) of the manufacturing area (3). Roll bar (1a, b) according to one of the preceding Claims 5 to 8th , characterized in that the teeth (2.7) of the phase region (7) over more than a width (9) of a Anfasbereiches (23) of the workpiece (20), in particular over the entire width of the toothing (2) of the manufacturing area (3) , extend. Roll bar (1a, b) after Claim 9 , characterized in that at the Anfasbereich (23) at the end of the workpiece (20), the teeth (2.7) of the phase region (7) viewed in the working direction (10) over the teeth (2.3) of the manufacturing area (3) also extend. Rolling rod (1a, b) according to one of Claims 9 or 10 , characterized in that in the Anfasbereich (23) in the axially central region of the workpiece (20), the teeth (2.7) of the phase region (7) viewed in the working direction (10) maximum up to the height of the teeth (2,3) of Manufacturing area (3) extend. Rolling rod (1a, b) according to one of Claims 9 to 11 Characterized in that - the shape of the teeth (2.7) of the phase portion (7) which corrected by the elastic part of the deformation negative image of the shape of the teeth (22.7) on the workpiece in Anfasbereich (23), and - the spaces between the teeth (2.7) of the phase region (7) at the beginning of the chamfering are not completely filled by the beginnings (21a) of the teeth (22 ') of the workpiece (20') after having passed through only the production region (3). Roll bar (1a, b) according to one of the preceding Claims 5 to 12 , characterized in that viewed in the working direction (10), the course direction (14.7) of the teeth (2.7) of the phase region (7) coincides with the course direction (14.3) of the teeth (2.3) of the production region (3). Method for producing a toothing (21) having a chamfering area (23) on the circumference of an associated, in particular rotationally symmetrical, workpiece (20) by means of at least one rolling bar (1a, b) integral with the width (9) of the toothing (2) in the working direction (10) applied 20 profiling, in particular toothing (2), characterized in that after the production of the toothing (21 ') without chamfering on the workpiece (20) the Anfasbereich (23) of the teeth (22') by means of the same Width (9) of the toothing (2) integral rolling rod (1a, b) by forming the beginnings (22a) 25 of the teeth (22 ') is performed. Method according to Claim 14 , characterized in that between the production of the toothing (21 ') without chamfering on the workpiece (20) 30 and the production of Anfasbereiches (23) of the teeth (22'), the rolling rod (1a, b) radially relative to the center of the workpiece ( 20) is changed in their position. Method according to one of Claims 14 or 15 , characterized in that the chamfering of the beginnings (22a) of the teeth (22) after relaxation of the toothing (21a) on the workpiece (20) is performed. A method according to any one of claims 14 to 16, characterized in that during the deformation of the starts (22a) of the teeth (22 ') the displaced material is moved towards the beginning (22a) of the teeth (22').

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