EP2760605B1 - Method and apparatus for manufacturing a gear wheel with stub toothing - Google Patents

Method and apparatus for manufacturing a gear wheel with stub toothing Download PDF

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Publication number
EP2760605B1
EP2760605B1 EP12766888.7A EP12766888A EP2760605B1 EP 2760605 B1 EP2760605 B1 EP 2760605B1 EP 12766888 A EP12766888 A EP 12766888A EP 2760605 B1 EP2760605 B1 EP 2760605B1
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Prior art keywords
mould
die
parts
tooth
calibration
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EP12766888.7A
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German (de)
French (fr)
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EP2760605A1 (en
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Jens POSPISCHIL
Anton Schmid
Norbert KOTULLA
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Sona BLW Prazisionsschmiede GmbH
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Sona BLW Prazisionsschmiede GmbH
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/28—Making machine elements wheels; discs
    • B21K1/30—Making machine elements wheels; discs with gear-teeth

Definitions

  • Method and apparatus for producing a gear wheel with short gearing wherein in a first forming step a Gangradrati is forged in the die and the short gearing in at least one other forming stage by cold calibration in the die by means of a molding tool with fan-like arranged moldings, pierce the mold ends in the interdental spaces, finished becomes.
  • a known device JP 2258130 A of the type mentioned has in the radial direction to the die axis movable moldings, which are guided between an upper and a lower receiving plate and which together with their inner ends form a calibration tool for calibrating the short teeth.
  • the present invention has the object to significantly improve the accuracy of the short teeth on a device and on a method of the type mentioned in the production of the short teeth of a gear wheel and thereby to ensure a trouble-free permanent die insert.
  • the production process as such, it should in particular enable a high production rate with long service life of the die components.
  • the gear wheel body is resiliently pressed against the upper receiving plate under a hydraulic load during the cold calibration, while the molded parts are displaced inwardly against a stop between the upper and lower receiving plates.
  • a method variant which is particularly suitable with regard to the tool life and precision of the short toothing produced is that the short toothing is formed in two calibration steps, wherein the teeth of the short toothing are formed with axially parallel tooth flanks in a first calibration step and in a second calibration step by means of the molded parts of the molding tool finished with undercut of the tooth flanks and subsequent fatigueausrundung finished.
  • the initially axially parallel forged tooth flanks of the short toothing advantageously receive their undercut only through the calibration step by means of the diversified molding tool.
  • the mold parts of the mold are individual flat sliding parts, which are arranged circumferentially in axial planes corresponding to the Gesenkachse with the circumferential pitch of the short toothing corresponding angular distances and with high accuracy between an upper and a guided lower receiving plate of the die and in a direction radially inward from a starting position in a finished tooth shape corresponding end position are displaceable, wherein the displacement of the sliding parts is directed obliquely to the die axis approximately against the foot region of the short teeth.
  • a suitable slope of the sliding direction is between 5 ° and 20 °, preferably between 10 ° and 15 ° and more preferably about 12 °.
  • the sliding parts are moved both radially and axially until reaching a radially inner stop position.
  • upper and lower receiving plate are firmly connected and limit guides for receiving the sliding parts and that - in a further embodiment - the lower receiving plate on its radially inner side ends with a gear wheel body facing collar part, the radially outer peripheral surface serves as a stop in the end position of the sliding parts.
  • the collar part has the additional advantage that its upper side forms a seat for supporting an annular projection of the Gangrad stressess, so the Gesenkstatik is useful.
  • a sliding parts enveloping the outside actuating ring, in the vertical displacement of the Sliding parts via interlocking conical pressure surfaces on sliding parts and actuating ring in its final position are displaced until it rests against the circumference of the collar part.
  • Fig. 1 shows the construction of a first Kalibriergesenks for cold calibration of the short teeth of a gear wheel for a manual transmission.
  • a forged in a previous forging gear body 1 is inserted into the first Kalibriergesenk.
  • the already formed in the forging die (not shown) teeth of the short teeth are improved in terms of their dimensional accuracy.
  • This improvement is in addition to a high dimensional accuracy of the radial dimensions, in particular, that the Teeth 15 (see. Fig. 4 ) in the region of the tooth head 22 a precise roof shape with sharply formed roof edges 40 obtained.
  • each tooth 15 run parallel to each other from the tooth head to the tooth root, ie, the teeth have after the first forming step of the cold calibration in the first Kalibriergesenk according to Fig. 1 a constant over their entire length tooth width.
  • the Gesenk inconvenience after Fig. 1 comprises from top to bottom a hold-down 2, which rests on the Gangradmaschine 1, which is in turn received from below in the die 3 of the lower die.
  • An ejector 4 engages with its upper end in the central bore 5 of the Gangrad stressess 1 by being received with a peripheral edge 6 of its end face in an extension of the central bore 5.
  • Downholder 2 and die 3 are each fitted within cylindrical housing parts. In this way, the hold-down 2 is guided within a guide ring 7 and the die 3 is fixed within a first Gesenkrings 8, which in turn sits within an outer Gesenkrings 9, which is connected by screws 12 to a base plate 10. A bearing on the base plate 10 die plate 11 on which the die 3 is mounted, engages in the inner die ring.
  • the Gangradoasa 1 has a central bore 5 surrounding hub portion 13, which ends at the bottom with a cone portion 14.
  • the outer cone of the cone part 14 is used when switching the gear wheel to adapt the rotational speed of a coupling sleeve to that of the gear wheel by means of a synchronizer ring, the inner cone auf216 on the outer cone 41 of the cone part 14.
  • Fig. 4 the outer cone 41 of the cone part 14 on a gear wheel 1 with ready-formed short teeth 15 is clearly shown.
  • a toothed body 17 connects radially outwardly via a spacer channel 16, on the outer circumference of the short teeth 15 as in Fig. 4 shown, is formed.
  • a stop ring 19 which limits the axial movement of the coupling sleeve. Only then continues in the radial direction outward, a relatively wide spacer groove 20 to the outer gear body 21 toward, which is provided for the yet to be produced by cutting the drive gear of the gear wheel.
  • first Kalibriergesenks succeeds to precisely shape the short teeth of the forged Gangrad stresses, both in the area of the roof-shaped tooth heads 22 (see. Fig. 4 ) as well as in the area of the tooth flanks, but there initially still with parallel tooth flanks.
  • Theirs (in Fig. 4 shown) bevel with corresponding expansion of the interdental spaces in each case towards the tooth root is produced only in the second calibration step by using a molding tool with fan-shaped parts, as in FIG Fig. 2 shown.
  • this mold 23 which substantially the lower die of Kalibriergesenks according to Fig. 2 forms oblique tooth flanks are generated, as in Fig. 4 shown on the finished short gearing.
  • the molding tool 23 is, as will be described in detail below, provided to process the intermediate spaces of the short teeth such that from the region of the tooth flanks by material displacement material from the tooth flanks in the Gesenkhohlform in toward the Zahnfuß Scheme, ie to the gutter 18 is displaced.
  • the calibration die according to Fig. 2 comprises between a pressure plate 25 of the upper die and an outer support ring 26 of the lower die a hold-down 27 which is depressed by the pressure plate 25 by means of elastomeric compression springs 28.
  • the hold-down 27 is designed with its lower mold surface such that it engages over the entire surface in the shape of the Gangrad stressess 1 and holds in this way the Gangrad redesign 1 with its outer gear body 21 in support on an upper receiving plate 29.
  • the upper receiving plate 29 is fixedly connected to a lower receiving plate 30, in which guides to allow a radial displacement movement are incorporated by sliding parts 31.
  • the sliding parts 31 have in their radially outer region upwardly to the die axis conically projecting pressure surfaces 32, which cooperate with correspondingly formed pressure surfaces 33 of an associated with the pressure plate 25 via screws 34 actuating ring 35. Accordingly, the sliding members 31 are displaced inward in the radial direction when the actuating ring 35 with the pressure plate 25 moves down to the hold-down 27 by means of the springs 28 reaches its lower end position.
  • the sliding parts 31 each have a forming end 36, which causes the formation of the interdental spaces in the inner position of the sliding parts 31 by piercing into this and causes the undercut of the short teeth in the flank region of the teeth.
  • Each sliding part 31 serves to form only one interdental space, which is limited by the two flanks of adjacent teeth.
  • these are precisely guided between the upper receiving plate 29 and the lower receiving plate 30, so that the formation of an exact tooth shape is ensured.
  • the exact inner end position of the sliding parts is ensured by a stop which is formed on the lower receiving plate 30.
  • the lower receiving plate 30 terminates on its radially inner ren side with a gear wheel body 1 facing collar part 37, the radially outer peripheral surface 38 serves as a stop in the inner end position of the sliding parts 31.
  • the slope of the sliding direction of the sliding parts 31 is advantageously between 5 ° and 20 °, using the example of FIG Fig. 2 shown Kalibriergesenks about 12 °.
  • the collar 37 of the lower receiving plate 30 is used with its upper end face of the support of the toothed body 17 of the Gangrad stressess 1, so that disturbing vibrations in the engagement region of the molding ends 36 of the sliding parts 31 are avoided.
  • the in Fig. 3 shown schematic section to Fig. 2 represents a sliding part 31 in two positions of its inner edge, namely in dashed lines in the retracted starting position PA and with solid lines in its shaping end position PE.
  • Above the molding end 36, namely between its upper contour and the adjacent spacer channel 16 there is a narrow die cavity into which excess material formed during the shaping of the interdental space can flow without material overlaps occurring.
  • This favorable displacement direction of the material results from the fact that the sliding part is guided obliquely upwards towards the die axis, so that the explained direction of the material displacement into the tooth root area and, if necessary, into the spacing channel 16 necessarily results.
  • Fig. 3 can be seen also the axial extent of the sliding part 31, namely to the lower edge 39, which rests in a groove in the lower receiving plate 30 and is slidably mounted within this groove.
  • end position PE of the sliding part corresponds to its representation in Fig. 2 , right side.
  • dashed drawn retracted position PA corresponds to the representation of the sliding part 31 according to Fig. 2 , left side.
  • the attachment of the upper receiving plate 29 on the lower receiving plate 30 is not shown in detail in the drawing.
  • the upper receiving plate 29 is as continuous annular plate formed, wherein it limits the guide of the sliding parts 31 upwards with its underside, such that the sliding parts 31 are guided on all sides.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)
  • Gears, Cams (AREA)

Description

Verfahren und Vorrichtung zur Herstellung eines Gangrads mit Kurzverzahnung, wobei in einer ersten Umformstufe ein Gangradkörper im Gesenk geschmiedet wird und die Kurzverzahnung in wenigstens einer weiteren Umformstufe durch Kaltkalibrieren im Gesenk mittels eines Formwerkzeugs mit fächerartig angeordneten Formteilen, deren Formenden in die Zahnzwischenräume einstechen, fertig geformt wird.Method and apparatus for producing a gear wheel with short gearing, wherein in a first forming step a Gangradkörper is forged in the die and the short gearing in at least one other forming stage by cold calibration in the die by means of a molding tool with fan-like arranged moldings, pierce the mold ends in the interdental spaces, finished becomes.

Eine bekannte Vorrichtung ( JP 2258130 A ) der eingangs genannten Art besitzt in radialer Richtung zur Gesenkachse verfahrbare Formteile, welche zwischen einer oberen und einer unteren Aufnahmeplatte geführt sind und welche mit ihren inneren Enden zusammen ein Kalibrierwerkzeug zum Kalibrieren der Kurzverzahnung bilden.A known device ( JP 2258130 A ) of the type mentioned has in the radial direction to the die axis movable moldings, which are guided between an upper and a lower receiving plate and which together with their inner ends form a calibration tool for calibrating the short teeth.

Dem gegenüber liegt der vorliegenden Erfindung die Aufgabe zugrunde, an einer Vorrichtung und an einem Verfahren der eingangs genannten Art bei der Herstellung der Kurzverzahnung eines Gangrads die Genauigkeit der Kurzverzahnung deutlich zu verbessern und dabei einen störungsfreien dauerhaften Gesenkeinsatz zu gewährleisten. Was das Herstellungsverfahren als solches betrifft, so soll es insbesondere eine hohe Produktionsrate bei langen Standzeiten der Gesenkbauteile ermöglichen.In contrast, the present invention has the object to significantly improve the accuracy of the short teeth on a device and on a method of the type mentioned in the production of the short teeth of a gear wheel and thereby to ensure a trouble-free permanent die insert. As regards the production process as such, it should in particular enable a high production rate with long service life of the die components.

Diese Aufgabe wird mit einem Verfahren der eingangs genannten Art erfindungsgemäß dadurch gelöst, dass die Formteile des Formwerkzeugs gemeinsam zwischen einer den Aufnahmeplatten in einer Richtung radial nach innen und schräg zum Fußbereich der Zähne hin bewegt werden, derart, dass für die präzise Ausbildung der Zähne der Kurzverzahnung durch Kaltkalibrieren überschüssiges Material aus dem Bereich der Zahnflanken in die Zahnfußbereiche in einen an den Fußraum angrenzenden Gesenkhohlraum verdrängt wird. Dabei entsteht durch Materialumformung eine Kurzverzahnung mit hoher Formgenauigkeit sowohl der eigentlichen Zahnform als auch der Zahnzwischenräume.This object is achieved with a method of the type mentioned in the present invention that the mold parts of the mold are moved together between a receiving plates in a direction radially inward and obliquely to the foot of the teeth, such that for the precise formation of the teeth Short gearing by cold calibration Excess material is displaced from the region of the tooth flanks in the Zahnfußbereiche in a cavity adjacent to the footwell Gesenklohlraum. This results in a short toothing with high dimensional accuracy of both the actual tooth shape and the interdental spaces by material deformation.

In Folge der mit dem erfindungsgemäßen Verfahren erzielten Materialumformung kommt es zu einer vollständigen Füllung der Gesenkhohlform im Bereich der Zahnköpfe. Durch die dabei erreichte scharfkantige Ausbildung der Unterkanten der Dachflächen im Bereich der Zahnköpfe - in Verbindung mit dem Hinterschnitt der Zahnflanken - werden zuverlässig Gangfehler durch axiales Trennen der geschalteten Antriebsverbindung, sog. Gangspringer, vermieden.As a result of the material deformation achieved by the method according to the invention, a complete filling of the die cavity mold in the region of the tooth heads occurs. Due to the achieved thereby sharp-edged formation of the lower edges of the roof surfaces in the region of the tooth heads - in conjunction with the undercut of the tooth flanks - reliably errors by axial separation of the switched drive connection, so-called. Gang Jumpers avoided.

Dabei wird die als nachteilig erkannte Überlappung des Materials als Folge einer Kaltumformung mit nur oberflächlicher Materialverschiebung vermieden.In this case, the overlap of the material, which is recognized as disadvantageous, is avoided as a consequence of cold forming with only superficial material displacement.

Um ein präzises Arbeiten der Formteile zu gewährleisten wird erfindungsgemäß vorgeschlagen, dass der Gangradkörper während des Kaltkalibrierens gegen die obere Aufnahmeplatte unter einer hydraulischen Last federnd angepresst wird, während die Formteile zwischen oberer und unterer Aufnahmeplatte gegen einen Anschlag nach innen verschoben werden. Durch das federnde Anpressen werden die beiden Aufnahmeplatten axial fixiert.In order to ensure precise working of the moldings, it is proposed according to the invention that the gear wheel body is resiliently pressed against the upper receiving plate under a hydraulic load during the cold calibration, while the molded parts are displaced inwardly against a stop between the upper and lower receiving plates. By the resilient pressing the two mounting plates are axially fixed.

Auf die Genauigkeit der Zahnausformung hat die Kinematik der Verschiebung der Formteile maßgeblichen Einfluss. Vorteilhaft ist deren gleichzeitige und gleichmäßige Verschiebung mittels eines vertikal betätigbaren Betätigungsrings über ineinander greifende kegelförmige Druckflächen an Formteilen und Betätigungsring, so dass die Formenden der Formteile stets unter gleichbleibenden Bedingungen in die Zahnzwischenräume hinein gedrückt werden. Dabei ist eine enge Führung der Formteile zwischen oberer und unterer Aufnahmeplatte besonders vorteilhaft.On the accuracy of Zahnausformung the kinematics of the displacement of the molded parts has a significant influence. Advantageous is their simultaneous and uniform displacement by means of a vertically operable actuating ring via interlocking conical pressure surfaces of moldings and actuating ring, so that the mold ends of the moldings are always pressed under constant conditions in the interdental spaces. In this case, a close management of the molded parts between the upper and lower receiving plate is particularly advantageous.

Eine hinsichtlich Standzeit des Gesenks einerseits und Präzision der hergestellten Kurzverzahnung andererseits besonders geeignete Verfahrensvariante besteht darin, dass die Kurzverzahnung in zwei Kalibrierschritten geformt wird, wobei die Zähne der Kurzverzahnung in einem ersten Kalibrierschritt mit achsparallelen Zahnflanken geformt und in einem zweiten Kalibrierschritt mittels der Formteile des Formwerkzeugs mit Hinterschnitt der Zahnflanken und anschließender Fußausrundung fertig kalibriert werden.A method variant which is particularly suitable with regard to the tool life and precision of the short toothing produced is that the short toothing is formed in two calibration steps, wherein the teeth of the short toothing are formed with axially parallel tooth flanks in a first calibration step and in a second calibration step by means of the molded parts of the molding tool finished with undercut of the tooth flanks and subsequent Fußausrundung finished.

Diesen zwei Kalibrierschritten geht als erster Umformschritt das Schmieden der Kurzverzahnung im Gesenk voraus. Dabei gelingt es, die Kurzverzahnung im Kopfbereich mit Bezug auf die Dachform der Zähne weitgehend fertig herzustellen, d.h. die spätere Umformarbeit durch die nachfolgenden Kalibrierschritte im Interesse einer Steigerung der Formgenauigkeit und der Standzeit der Gesenke auf ein Mindestmaß zu beschränken.These two calibration steps are preceded by the forging of the short toothing in the die as the first forming step. It is possible to produce the short teeth in the head area with respect to the roof shape of the teeth largely finished, ie the subsequent forming work by the subsequent calibration steps in the interest of increasing the dimensional accuracy and the To limit the life of the dies to a minimum.

Die zunächst achsparallel geschmiedeten Zahnflanken der Kurzverzahnung erhalten vorteilhaft ihren Hinterschnitt erst durch den Kalibrierschritt mittels des gefächerten Formwerkzeugs.The initially axially parallel forged tooth flanks of the short toothing advantageously receive their undercut only through the calibration step by means of the diversified molding tool.

Bei einer Vorrichtung zur Durchführung des erfindungsgemäßen Verfahrens der eingangs genannten Art ist vorgesehen, dass die Formteile des Formwerkzeugs einzelne flache Schiebeteile sind, welche umlaufend in zur Gesenkachse axialen Ebenen mit der Umfangsteilung der Kurzverzahnung entsprechenden Winkelabständen angeordnet sind und mit hoher Genauigkeit zwischen einer oberen und einer unteren Aufnahmeplatte des Gesenks geführt und in einer Richtung nach radial innen aus einer Ausgangsposition in eine der fertigen Zahnform entsprechende Endposition verschiebbar sind, wobei die Verschiebung der Schiebeteile schräg zur Gesenkachse etwa gegen den Fußbereich der Kurzverzahnung gerichtet ist.In an apparatus for carrying out the method according to the invention of the type mentioned above, it is provided that the mold parts of the mold are individual flat sliding parts, which are arranged circumferentially in axial planes corresponding to the Gesenkachse with the circumferential pitch of the short toothing corresponding angular distances and with high accuracy between an upper and a guided lower receiving plate of the die and in a direction radially inward from a starting position in a finished tooth shape corresponding end position are displaceable, wherein the displacement of the sliding parts is directed obliquely to the die axis approximately against the foot region of the short teeth.

Eine geeignete Schräge der Schieberichtung beträgt zwischen 5° und 20°, bevorzugt zwischen 10° und 15° und besonders bevorzugt etwa 12°. Dabei werden die Schiebeteile sowohl radial als auch axial bewegt bis zum Erreichen einer radial inneren Anschlagposition.A suitable slope of the sliding direction is between 5 ° and 20 °, preferably between 10 ° and 15 ° and more preferably about 12 °. The sliding parts are moved both radially and axially until reaching a radially inner stop position.

Mit dem Ziel eines möglichst vibrationsfreien, durch Biegekräfte weitgehend unbeeinflussten Verfahrensablaufs wird erfindungsgemäß ferner vorgeschlagen, dass obere und untere Aufnahmeplatte fest miteinander verbunden sind und Führungen für die Aufnahme der Schiebeteile begrenzen und dass - in einer weiteren Ausgestaltung - die untere Aufnahmeplatte auf ihrer radial inneren Seite mit einem zum Gangradkörper hinweisenden Kragenteil endet, dessen radial äußere Umfangsfläche als Anschlag in der Endposition der Schiebeteile dient.With the aim of a possible vibration-free, by bending forces largely uninfluenced process sequence is further proposed according to the invention that upper and lower receiving plate are firmly connected and limit guides for receiving the sliding parts and that - in a further embodiment - the lower receiving plate on its radially inner side ends with a gear wheel body facing collar part, the radially outer peripheral surface serves as a stop in the end position of the sliding parts.

Der Kragenteil bietet den zusätzlichen Vorteil, dass dessen Oberseite einen Sitz zur Auflage eines ringförmigen Vorsprungs des Gangradkörpers bildet, also der Gesenkstatik dienlich ist.The collar part has the additional advantage that its upper side forms a seat for supporting an annular projection of the Gangradkörpers, so the Gesenkstatik is useful.

Auf diese Weise gelingt es, einen Gesenkaufbau zu verwirklichen, mit welchem unter Berücksichtigung der speziellen Querschnittsform des jeweiligen Gangrads die Zielsetzung der vorliegenden Erfindung optimal erreichbar ist.In this way, it is possible to realize a Gesenkaufbau, with which, taking into account the specific cross-sectional shape of the respective gear wheel, the objective of the present invention is optimally achievable.

Zur Betätigung der Schiebeteile eignet sich besonders vorteilhaft ein die Schiebeteile außen einhüllender Betätigungsring, bei dessen vertikaler Versetzung die Schiebeteile über ineinander greifende konische Druckflächen an Schiebeteilen und Betätigungsring in ihre Endposition bis zur Anlage am Umfang des Kragenteils verschiebbar sind.To actuate the sliding parts is particularly advantageous a sliding parts enveloping the outside actuating ring, in the vertical displacement of the Sliding parts via interlocking conical pressure surfaces on sliding parts and actuating ring in its final position are displaced until it rests against the circumference of the collar part.

Im Folgenden wird ein Ausführungsbeispiel der Erfindung anhand der Zeichnung erläutert. Es zeigt

Fig. 1
Einen Axialschnitt durch ein erstes Kalibriergesenk
Fig. 2
Einen Axialschnitt durch ein zweites Kalibriergesenk
Fig. 3
Eine vergrößerte Teilansicht zu Fig. 2 und
Fig. 4
Eine perspektivische Ansicht des Gangrads nach Fertigstellung der Kurzverzahnung
In the following an embodiment of the invention will be explained with reference to the drawing. It shows
Fig. 1
An axial section through a first calibration die
Fig. 2
An axial section through a second calibration die
Fig. 3
An enlarged partial view too Fig. 2 and
Fig. 4
A perspective view of the gear wheel after completion of the short gearing

Fig. 1 zeigt den Aufbau eines ersten Kalibriergesenks zum Kaltkalibrieren der Kurzverzahnung eines Gangrads für ein Schaltgetriebe. Fig. 1 shows the construction of a first Kalibriergesenks for cold calibration of the short teeth of a gear wheel for a manual transmission.

In dieser Umformstufe, auf welche ein zweiter Kalibrierschritt, wie in Fig. 2 dargestellt, folgt, wird ein in einem vorangegangenen Schmiedegesenk geschmiedeter Gangradkörper 1 in das erste Kalibriergesenk eingelegt. Dabei werden die bereits im Schmiedegesenk (nicht dargestellt) ausgeformten Zähne der Kurzverzahnung hinsichtlich ihrer Formgenauigkeit verbessert. Diese Verbesserung besteht neben einer hohen Maßgenauigkeit der radialen Abmessungen insbesondere darin, dass die Zähne 15 (vgl. Fig. 4) im Bereich des Zahnkopfes 22 eine präzise Dachform mit scharf ausgebildeten Dachkanten 40 erhalten. Die Zahnflanken auf beiden Seiten jedes Zahns 15 verlaufen vom Zahnkopf zum Zahnfuß hin parallel zueinander, d.h. die Zähne besitzen nach dem ersten Umformschritt des Kaltkalibrierens im ersten Kalibriergesenk gemäß Fig. 1 eine über ihre gesamte Länge gleichbleibende Zahnbreite.In this forming stage, to which a second calibration step, as in Fig. 2 is shown, a forged in a previous forging gear body 1 is inserted into the first Kalibriergesenk. In this case, the already formed in the forging die (not shown) teeth of the short teeth are improved in terms of their dimensional accuracy. This improvement is in addition to a high dimensional accuracy of the radial dimensions, in particular, that the Teeth 15 (see. Fig. 4 ) in the region of the tooth head 22 a precise roof shape with sharply formed roof edges 40 obtained. The tooth flanks on both sides of each tooth 15 run parallel to each other from the tooth head to the tooth root, ie, the teeth have after the first forming step of the cold calibration in the first Kalibriergesenk according to Fig. 1 a constant over their entire length tooth width.

Der Gesenkaufbau nach Fig. 1 umfasst von oben nach unten einen Niederhalter 2, welcher auf dem Gangradkörper 1 aufsitzt, der wiederum von unten in der Matrize 3 des Untergesenks aufgenommen ist. Ein Auswerfer 4 greift mit seinem oberen Ende in die Mittelbohrung 5 des Gangradkörpers 1 ein, indem er mit einem umlaufenden Rand 6 seiner Stirnseite in einer Erweiterung der Mittelbohrung 5 aufgenommen ist.The Gesenkaufbau after Fig. 1 comprises from top to bottom a hold-down 2, which rests on the Gangradkörper 1, which is in turn received from below in the die 3 of the lower die. An ejector 4 engages with its upper end in the central bore 5 of the Gangradkörpers 1 by being received with a peripheral edge 6 of its end face in an extension of the central bore 5.

Niederhalter 2 und Matrize 3 sind jeweils innerhalb zylindrischer Gehäuseteile eingepasst. Auf diese Weise ist der Niederhalter 2 innerhalb eines Führungsrings 7 geführt und die Matrize 3 ist innerhalb eines ersten Gesenkrings 8 fixiert, der wiederum innerhalb eines äußeren Gesenkrings 9 sitzt, welcher mittels Schrauben 12 mit einer Grundplatte 10 verbunden ist. Eine auf der Grundplatte 10 lagernde Gesenkplatte 11, auf welcher die Matrize 3 gelagert ist, greift in den inneren Gesenkring ein.Downholder 2 and die 3 are each fitted within cylindrical housing parts. In this way, the hold-down 2 is guided within a guide ring 7 and the die 3 is fixed within a first Gesenkrings 8, which in turn sits within an outer Gesenkrings 9, which is connected by screws 12 to a base plate 10. A bearing on the base plate 10 die plate 11 on which the die 3 is mounted, engages in the inner die ring.

Der Gangradkörper 1 besitzt einen seine Mittelbohrung 5 umgebenden Nabenteil 13, der nach unten hin mit einem Konusteil 14 endet. Der Außenkonus des Konusteils 14 dient beim Schalten des Gangrads zur Anpassung der Rotationsgeschwindigkeit einer Kupplungsmuffe an die des Gangrads mittels eines Synchronrings, dessen Innenkonus auf den Außenkonus 41 des Konusteils 14 auffährt. In Fig. 4 ist der Außenkonus 41 des Konusteils 14 an einem Gangrad 1 mit fertig geformter Kurzverzahnung 15 deutlich dargestellt.The Gangradkörper 1 has a central bore 5 surrounding hub portion 13, which ends at the bottom with a cone portion 14. The outer cone of the cone part 14 is used when switching the gear wheel to adapt the rotational speed of a coupling sleeve to that of the gear wheel by means of a synchronizer ring, the inner cone auffährt on the outer cone 41 of the cone part 14. In Fig. 4 the outer cone 41 of the cone part 14 on a gear wheel 1 with ready-formed short teeth 15 is clearly shown.

An den Konusteil 14 des Nabenteils 13 schließt sich radial nach außen hin über eine Abstandsrinne 16 ein Verzahnungskörper 17 an, an dessen Außenumfang die Kurzverzahnung 15 wie in Fig. 4 dargestellt, angeformt ist. Weiter in radialer Richtung nach außen schließt sich an den Verzahnungskörper 17 außerhalb der Kurzverzahnung 15 über eine schmale Abstandsrinne 18 ein Anschlagring 19 an (vgl. Fig. 4), welcher die Axialbewegung der Kupplungsmuffe begrenzt. Erst daran schließt sich weiter in radialer Richtung nach außen eine relativ breite Distanzrinne 20 zum äußeren Zahnradkörper 21 hin an, welcher für die noch spanabhebend zu erzeugende Antriebsverzahnung des Gangrads vorgesehen ist. Mittels des in Fig. 1 schematisch dargestellten ersten Kalibriergesenks gelingt es, die Kurzverzahnung des geschmiedeten Gangradkörpers präzise auszuformen, sowohl im Bereich der dachförmigen Zahnköpfe 22 (vgl. Fig. 4) als auch im Bereich der Zahnflanken, dort zunächst aber noch mit parallelen Zahnflanken. Deren (in Fig. 4 gezeigte) Schräge mit entsprechender Erweiterung der Zahnzwischenräume jeweils zum Zahnfuß hin wird erst im zweiten Kalibrierschritt durch Einsatz eines Formwerkzeugs mit fächerartig angeordneten Formteilen erzeugt, wie in Fig. 2 dargestellt. Mittels dieses Formwerkzeugs 23, welches im wesentlichen das Untergesenk des Kalibriergesenks gemäß Fig. 2 bildet, werden schräge Zahnflanken erzeugt, wie in Fig. 4 an der fertigen Kurzverzahnung dargestellt. Diese Hinterschneidung der Zähne 15 der Kurzverzahnung im Bereich ihrer Seitenflanken 24, dient der Vermeidung von Gangspringern. Das Formwerkzeug 23 ist, wie noch im folgenden detailliert beschrieben wird, dazu vorgesehen, die Zwischenräume der Kurzverzahnung derart zu bearbeiten, dass aus dem Bereich der Zahnflanken durch entsprechende Materialverdrängung Material von den Zahnflanken in die Gesenkhohlform hinein in Richtung auf den Zahnfußbereich, also zur Abstandsrinne 18 hin verdrängt wird.To the conical part 14 of the hub part 13, a toothed body 17 connects radially outwardly via a spacer channel 16, on the outer circumference of the short teeth 15 as in Fig. 4 shown, is formed. Next in the radial direction outward adjoins the gear body 17 outside the short teeth 15 via a narrow spacer channel 18, a stop ring 19 (see. Fig. 4 ), which limits the axial movement of the coupling sleeve. Only then continues in the radial direction outward, a relatively wide spacer groove 20 to the outer gear body 21 toward, which is provided for the yet to be produced by cutting the drive gear of the gear wheel. By means of in Fig. 1 schematically illustrated first Kalibriergesenks succeeds to precisely shape the short teeth of the forged Gangradkörpers, both in the area of the roof-shaped tooth heads 22 (see. Fig. 4 ) as well as in the area of the tooth flanks, but there initially still with parallel tooth flanks. Theirs (in Fig. 4 shown) bevel with corresponding expansion of the interdental spaces in each case towards the tooth root is produced only in the second calibration step by using a molding tool with fan-shaped parts, as in FIG Fig. 2 shown. By means of this mold 23, which substantially the lower die of Kalibriergesenks according to Fig. 2 forms oblique tooth flanks are generated, as in Fig. 4 shown on the finished short gearing. This undercut of the teeth 15 of the short teeth in the region of their side edges 24, serves to avoid leaps. The molding tool 23 is, as will be described in detail below, provided to process the intermediate spaces of the short teeth such that from the region of the tooth flanks by material displacement material from the tooth flanks in the Gesenkhohlform in toward the Zahnfußbereich, ie to the gutter 18 is displaced.

Das Kalibriergesenk gemäß Fig. 2 umfasst zwischen einer Druckplatte 25 des Obergesenks und einem äußeren Stützring 26 des Untergesenks einen Niederhalter 27, der durch die Druckplatte 25 mittels elastomerer Druckfedern 28 niedergedrückt wird. Der Niederhalter 27 ist mit seiner unteren Formfläche derart gestaltet, dass er in die Form des Gangradkörpers 1 vollflächig eingreift und auf diese Weise den Gangradkörper 1 mit seinem äußeren Zahnradkörper 21 in Auflage auf einer oberen Aufnahmeplatte 29 hält. Die obere Aufnahmeplatte 29 ist fest mit einer unteren Aufnahmeplatte 30 verbunden, in welche Führungen zur Ermöglichung einer radialen Verschiebebewegung von Schiebeteilen 31 eingearbeitet sind. Die Schiebeteile 31 besitzen in ihrem radial äußeren Bereich nach oben zur Gesenkachse hin konisch vorspringende Druckflächen 32, welche mit entsprechend ausgebildeten Druckflächen 33 eines mit der Druckplatte 25 über Schrauben 34 verbundenen Betätigungsrings 35 zusammenwirken. Dem entsprechend werden die Schiebeteile 31 in radialer Richtung nach innen verschoben, wenn der Betätigungsring 35 mit der Druckplatte 25 nach unten fährt bis der Niederhalter 27 vermittels der Federn 28 seine untere Endposition erreicht. An ihrem inneren Ende besitzen die Schiebeteile 31 jeweils ein Formende 36, welches in der inneren Position der Schiebeteile 31 die Ausformung der Zahnzwischenräume bewirkt, indem es in diese einsticht und die Hinterschneidung der Kurzverzahnung im Flankenbereich der Zähne bewirkt. Jedes Schiebeteil 31 dient der Ausformung nur eines Zahnzwischenraums, welcher begrenzt wird von den beiden Flanken benachbarter Zähne. Für das Einstechen der Schiebeteile 31 sind diese präzise zwischen der oberen Aufnahmeplatte 29 und der unteren Aufnahmeplatte 30 geführt, so dass die Ausbildung einer exakten Zahnform gewährleistet ist. Durch die im vorangegangenen Kalibrierschritt gemäß Fig. 1 erzeugte hohe Genauigkeit der Form der Kurzverzahnung gelingt es für den zweiten Kalibrierschritt, die Belastung des Formwerkzeugs zugunsten einer hohen Standzeit desselben zu begrenzen. Die exakte innere Endposition der Schiebeteile wird durch einen Anschlag gewährleistet, der an der unteren Aufnahmeplatte 30 ausgebildet ist. Zu diesem Zweck endet die untere Aufnahmeplatte 30 auf ihrer radial inneren ren Seite mit einem zum Gangradkörper 1 hinweisenden Kragenteil 37, dessen radial äußere Umfangsfläche 38 als Anschlag in der inneren Endposition der Schiebeteile 31 dient.The calibration die according to Fig. 2 comprises between a pressure plate 25 of the upper die and an outer support ring 26 of the lower die a hold-down 27 which is depressed by the pressure plate 25 by means of elastomeric compression springs 28. The hold-down 27 is designed with its lower mold surface such that it engages over the entire surface in the shape of the Gangradkörpers 1 and holds in this way the Gangradkörper 1 with its outer gear body 21 in support on an upper receiving plate 29. The upper receiving plate 29 is fixedly connected to a lower receiving plate 30, in which guides to allow a radial displacement movement are incorporated by sliding parts 31. The sliding parts 31 have in their radially outer region upwardly to the die axis conically projecting pressure surfaces 32, which cooperate with correspondingly formed pressure surfaces 33 of an associated with the pressure plate 25 via screws 34 actuating ring 35. Accordingly, the sliding members 31 are displaced inward in the radial direction when the actuating ring 35 with the pressure plate 25 moves down to the hold-down 27 by means of the springs 28 reaches its lower end position. At its inner end, the sliding parts 31 each have a forming end 36, which causes the formation of the interdental spaces in the inner position of the sliding parts 31 by piercing into this and causes the undercut of the short teeth in the flank region of the teeth. Each sliding part 31 serves to form only one interdental space, which is limited by the two flanks of adjacent teeth. For the insertion of the sliding parts 31, these are precisely guided between the upper receiving plate 29 and the lower receiving plate 30, so that the formation of an exact tooth shape is ensured. By the in the previous calibration step according to Fig. 1 produced high accuracy of the shape of the short teeth succeeds for the second calibration step to limit the burden of the mold in favor of a long service life of the same. The exact inner end position of the sliding parts is ensured by a stop which is formed on the lower receiving plate 30. For this purpose, the lower receiving plate 30 terminates on its radially inner ren side with a gear wheel body 1 facing collar part 37, the radially outer peripheral surface 38 serves as a stop in the inner end position of the sliding parts 31.

Es ist besonders vorteilhaft, die Schiebeteile 31 derart zu führen, dass sie bei ihrer formgebenden Radialbewegung zur Gesenkachse hin schräg zu dieser angestellt sind, derart, dass die Materialverdrängung im Bereich der Zahnzwischenräume nach oben hin in Richtung auf den Zahnfußbereich erfolgt, wo das überschüssige Material von den Zahnflanken in den Zahnfußbereich und evtl. in einen darüber anschließenden freien Gesenkhohlraum verdrängt werden kann, welcher sich unterhalb der Abstandsrinne 16 (Fig. 3) befindet.It is particularly advantageous to guide the sliding parts 31 such that they are employed in their shaping radial movement to the Gesenkachse obliquely to this, such that the material displacement in the region of the interdental spaces upwards toward the Zahnfußbereich where the excess material can be displaced from the tooth flanks in the Zahnfußbereich and possibly in an adjoining free Gesenkhohlraum, which is below the spacer channel 16 (FIG. Fig. 3 ) is located.

Die Schräge der Schieberichtung der Schiebeteile 31 beträgt vorteilhaft zwischen 5° und 20°, am Beispiel des in Fig. 2 dargestellten Kalibriergesenks etwa 12°.The slope of the sliding direction of the sliding parts 31 is advantageously between 5 ° and 20 °, using the example of FIG Fig. 2 shown Kalibriergesenks about 12 °.

Neben seiner Funktion als innerer Endanschlag für die Schiebeteile 31 dient der Kragen 37 der unteren Aufnahmeplatte 30 mit seiner oberen Stirnfläche der Auflage des Verzahnungskörpers 17 des Gangradkörpers 1, so dass störende Vibrationen im Eingriffsbereich der Formenden 36 der Schiebeteile 31 vermieden werden.In addition to its function as an inner end stop for the sliding parts 31, the collar 37 of the lower receiving plate 30 is used with its upper end face of the support of the toothed body 17 of the Gangradkörpers 1, so that disturbing vibrations in the engagement region of the molding ends 36 of the sliding parts 31 are avoided.

Der in Fig. 3 gezeigte schematische Ausschnitt zu Fig. 2 stellt ein Schiebeteil 31 in zwei Positionen seiner inneren Kante dar, nämlich in strichlierter Darstellung in der zurückgezogenen Ausgangsposition PA und mit durchgezogenen Linien in seiner formgebenden Endposition PE. Diese begrenzt die Schiebebewegung gemäß Pfeil P2 nach innen, wobei das Formende 36 des Schiebeteils 31 maximal in einen Zahnzwischenraum einsticht und dabei die Endform des Zwischenraums zwischen zwei benachbarten Zähnen ausformt. Oberhalb des Formendes 36, nämlich zwischen dessen oberer Kontur und der benachbarten Abstandsrinne 16 befindet sich ein schmaler Gesenkhohlraum, in welchen überschüssiges, das bei der Formgebung des Zahnzwischenraums umgeformte Material einfließen kann, ohne dass es dabei zu Materialüberlappungen kommt. Diese günstige Verlagerungsrichtung des Materials ergibt sich dadurch, dass das Schiebeteil zur Gesenkachse hin schräg nach oben verschiebbar geführt ist, so dass sich zwingend die erläuterte Richtung der Materialverschiebung in den Zahnfußbereich und ggf. noch in die Abstandsrinne 16 hinein ergibt.The in Fig. 3 shown schematic section to Fig. 2 represents a sliding part 31 in two positions of its inner edge, namely in dashed lines in the retracted starting position PA and with solid lines in its shaping end position PE. This limits the sliding movement according to arrow P2 inwards, wherein the forming end 36 of the sliding part 31 punctures maximally in a tooth space and thereby forms the final shape of the gap between two adjacent teeth. Above the molding end 36, namely between its upper contour and the adjacent spacer channel 16, there is a narrow die cavity into which excess material formed during the shaping of the interdental space can flow without material overlaps occurring. This favorable displacement direction of the material results from the fact that the sliding part is guided obliquely upwards towards the die axis, so that the explained direction of the material displacement into the tooth root area and, if necessary, into the spacing channel 16 necessarily results.

In Fig. 3 erkennt man auch die axiale Erstreckung des Schiebeteils 31, nämlich bis zur Unterkante 39, welche in einer Nut in der unteren Aufnahmeplatte 30 aufliegt und innerhalb dieser Nut verschiebbar gelagert ist. Die in Fig. 3 gezeigte Endposition PE des Schiebeteils entspricht dessen Darstellung in Fig. 2, rechte Seite. Die in Fig. 3 strichliert gezeichnete zurückgezogene Position PA entspricht der Darstellung des Schiebeteils 31 gemäß Fig. 2, linke Seite.In Fig. 3 can be seen also the axial extent of the sliding part 31, namely to the lower edge 39, which rests in a groove in the lower receiving plate 30 and is slidably mounted within this groove. In the Fig. 3 shown end position PE of the sliding part corresponds to its representation in Fig. 2 , right side. In the Fig. 3 dashed drawn retracted position PA corresponds to the representation of the sliding part 31 according to Fig. 2 , left side.

Die Befestigung der oberen Aufnahmeplatte 29 auf der unteren Aufnahmeplatte 30 ist in der Zeichnung nicht näher dargestellt. Die obere Aufnahmeplatte 29 ist als durchgehende ringförmige Platte ausgebildet, wobei sie mit ihrer Unterseite die Führung der Schiebeteile 31 nach oben begrenzt, derart, dass die Schiebeteile 31 allseitig geführt sind.The attachment of the upper receiving plate 29 on the lower receiving plate 30 is not shown in detail in the drawing. The upper receiving plate 29 is as continuous annular plate formed, wherein it limits the guide of the sliding parts 31 upwards with its underside, such that the sliding parts 31 are guided on all sides.

Das Gangrad mit fertig geformter Kurzverzahnung, wie in Fig. 4 dargestellt, kann nach dem Öffnen des Gesenks, d.h. mit in ihre Ausgangsposition PA zurückgesetzten Schiebeteilen und mit Abheben der Druckplatte 25, an deren Unterseite der Betätigungsring 35 befestigt ist, nach oben aus dem Untergesenk entnommen werden. Dabei weisen die Zahnköpfe 22 der Kurzverzahnung nach unten. Danach wird in einem spanabhebenden Verfahren die Antriebsverzahnung in den Zahnkörper 21 eingeschnitten. Es versteht sich von selbst, dass vorher der Außenumfang des Zahnkörpers 21 zusammen mit der Mittelbohrung des Gangrads und dem Konusteil 14 zentrisch bearbeitet werden.The gear wheel with finished short splines, as in Fig. 4 shown, after opening the die, that is, with reset to its original position PA sliding parts and lifting the pressure plate 25, at the bottom of the actuating ring 35 is attached, are removed upwards from the lower die. In this case, the tooth heads 22 of the short teeth down. Thereafter, the drive teeth are cut into the tooth body 21 in a machining process. It goes without saying that previously the outer circumference of the tooth body 21 are machined centrally together with the central bore of the gear wheel and the cone part 14.

Claims (10)

  1. A method for producing a gear wheel having short toothing for a manual gearbox, a gear-wheel body (1) being forged in a die in a first moulding stage and the moulding of the short toothing being finished in at least one further moulding stage by means of cold calibration in the die by means of a mould (23) with mould parts arranged in a fan-like manner, the mould ends of which penetrate into the tooth interspaces, the mould parts being guided together between an upper and a lower mounting plate (29, 30) and moved radially inwards in one direction,
    characterized
    in that the direction of penetration of the mould parts is chosen to slant towards the root area of the teeth (15), so that material is displaced out of the area of the tooth flanks into the tooth root areas and after complete filling of the die cavity, excessive material is displaced into a die cavity adjacent to the root area.
  2. The method according to Claim 1,
    characterized
    in that during the cold calibration, the gear-wheel body (1) is resiliently pressed against the upper mounting plate (29) under a hydraulic load, whilst the mould parts are displaced inwards between upper and lower mounting plates (29, 30) against a stop.
  3. The method according to Claim 1,
    characterized
    in that the mould parts can, by means of an actuating ring (35) which can be actuated vertically and by means of interengaging conical pressure surfaces (32, 33) on mould parts and actuating ring, be pushed, by way of the mould ends (36) thereof, into the tooth interspaces.
  4. The method according to Claim 1,
    characterized
    in that the short toothing is moulded in two calibration steps, wherein the teeth (15) of the short toothing are moulded in a first calibration step with parallel tooth flanks and the calibration thereof is finished in a second calibration step by means of the mould parts of the mould with undercut of the tooth flanks and subsequent root rounding.
  5. A device for carrying out the method according to Claims 1 to 5,
    having a first moulding stage, a gear-wheel body (1) being forged in the die in the first moulding stage, and at least one further moulding stage, the moulding of the short toothing being finished in the at least one further moulding stage by cold calibration in the die by means of a mould (23) with mould parts arranged in a fan-like manner, the mould ends of which penetrate into the tooth interspaces, the mould parts of the mould (23) being individual flat sliding parts (31), which are arranged circumferentially in planes axial to the die axis with angular spacings corresponding to the circumferential division of the short toothing and are guided between an upper and a lower mounting plate (29, 30) and can be displaced radially inwards in one direction from an initial position (PA) into an end position (PE) corresponding to the finished tooth shape,
    characterized
    in that the displacement of the sliding parts (31) is directed in a slanting manner with respect to the die axis, somewhat towards the root area of the short toothing.
  6. The device according to Claim 5,
    characterized
    in that the slant of the sliding direction is between 5° and 20°, preferably between 10° and 15°.
  7. The device according to Claim 5,
    characterized
    in that upper and lower mounting plates (29, 30) are securely connected to one another and delimit guides for the mounting of the sliding parts (23).
  8. The device according to Claim 5,
    characterized
    in that the lower mounting plate (30) ends on the radially inner side thereof with a collar part (37) facing towards the gear-wheel body (1), the radially outer circumferential surface (38) of which collar part is used as a stop in the end position (PE) of the sliding parts (31).
  9. The device according to Claim 8,
    characterized
    in that an annular projection (17) of the gear-wheel body (1) sits on the upper side of the collar part (37) of the lower mounting plate (30).
  10. The device according to Claim 5,
    characterized
    in that the sliding parts (31) can, by means of an actuating ring (35) which can be actuated vertically and by means of interengaging conical pressure surfaces (32, 33) on sliding parts and actuating ring, be displaced into the end position (PE) thereof.
EP12766888.7A 2011-09-29 2012-09-22 Method and apparatus for manufacturing a gear wheel with stub toothing Active EP2760605B1 (en)

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DE102011114504A DE102011114504A1 (en) 2011-09-29 2011-09-29 Method and device for producing a gear wheel with short toothing
PCT/EP2012/003968 WO2013045064A1 (en) 2011-09-29 2012-09-22 Method and apparatus for manufacturing a gear wheel with stub toothing

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DE102011114504A1 (en) 2013-04-04
JP2014528839A (en) 2014-10-30
US20140223985A1 (en) 2014-08-14
CN103998158A (en) 2014-08-20
CN103998158B (en) 2016-01-20
US9399251B2 (en) 2016-07-26
WO2013045064A1 (en) 2013-04-04
JP6087930B2 (en) 2017-03-01

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