JP2002307130A - Ring gear manufacturing method, and device used therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method and a manufacturing device for manufacturing a ring gear out of a plate stock by using a press. SOLUTION: This manufacturing method comprises a first step of manufacturing an intermediate product with the wall thickness of a necessary part larger than that of a completed product by compressing a unnecessary part which is finally removed in a stock, and moving the material of this part to other necessary parts, and a second step of compressing the part of large wall thickness to obtain the wall thickness of the completed product and cutting and removing the unnecessary part.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a ring gear for manufacturing a ring gear from a plate-like material using, for example, a press machine, and an apparatus used therefor.

[0002]

2. Description of the Related Art As a conventional technique relating to the production of this kind of ring gear, for example, a technique disclosed in Japanese Patent Application Laid-Open No. 9-248646 can be mentioned. According to the technique disclosed in this publication, an intermediate product (coarse die) having teeth formed on the outer periphery is formed by setting a ring-shaped flat plate material in a die and punching out with a punch. Next, the intermediate material is turned upside down and set on a die for the next step, and pressed by a punch from the opposite direction. The material is compressed or squeezed by this press, and the shoulders at the outer peripheral corners of the intermediate product generated in the punching step are corrected.

[0003]

In order to correct shoulder distortion of an intermediate product as described above, it is effective to increase the thickness of the portion where the material is compressed by a press for finishing in advance. It is a target. However, if the outer shape and thickness of the material are made larger than the dimensions required for the product in order to increase the thickness, the cost will increase. Even if the thickness of the intermediate product in the form of a flat plate is set to a relatively large thickness and compression is performed, a considerably large compression load is required to move the meat of the material toward the shoulder portion of the tooth tip. Even if this load is set to be large, the meat of the material does not always move toward the outer periphery of the intermediate product, and may move in the direction of the center hole having a small resistance.

An object of the present invention is to solve the above-mentioned problems, and one object of the present invention is to use an unnecessary portion of a raw material which does not affect the function of a manufactured product to increase a necessary portion of the manufactured product. It is. Another object of the present invention is to increase the precision of finishing by compressing a required portion with increased wall thickness to move the portion of the wall in a desired direction.

[0005]

SUMMARY OF THE INVENTION The present invention has been made to achieve the above object, and the invention according to claim 1 is a method for manufacturing a ring gear, which does not affect the function of a manufactured product in a material. Unnecessary meat is moved to the required part of the manufactured product. This allows unnecessary parts of the material to be
This is advantageous because it can be used to increase the thickness of a required part in a manufactured product.

According to a second aspect of the present invention, there is provided a method of manufacturing a ring gear, wherein an unnecessary portion which is finally removed from a raw material is subjected to compression processing so that the meat of the unnecessary portion is directed to another necessary portion. A first step of moving and producing an intermediate product in which the thickness of the necessary portion is larger than the finished product, and compressing the required portion to a thickness of the finished product and cutting and removing the unnecessary portion. And a second step. As described above, in the first step, an intermediate product in which the thickness of the necessary portion is larger than that of the finished product is formed, and in the second step, the thickness of the necessary portion is made the thickness of the finished product, whereby the material By utilizing the thickness of the unnecessary portion, the finishing accuracy of the necessary portion can be improved.

According to a third aspect of the present invention, there is provided a method of manufacturing a ring gear, wherein a center portion of a material for manufacturing the ring gear, which is finally punched out and becomes a center hole of the ring gear, is compressed. A first step of moving the meat of the central portion toward the outer peripheral portion of the material to be the tooth portion of the ring gear to produce an intermediate product having a thickness of the outer peripheral portion larger than that of the finished product; and compressing the outer peripheral portion. And forming a center hole by punching out the central portion. According to the present invention, the portion of the shoulder of the tooth tip generated when the tooth portion of the ring gear is formed on the outer peripheral portion of the material is filled with the meat of the material by the compression molding in the second step, thereby forming the tooth portion. Accuracy can be increased.

According to a fourth aspect of the present invention, there is provided the method of manufacturing a ring gear according to the third aspect, wherein in the first step, a concave portion is formed by compressing a central portion of the material. In the second step, the outer peripheral portion of the material on which the teeth are formed is compressed to a thickness of the finished product, so that the outer peripheral portion is filled with the concave portions and the tips of the teeth. Move. Thus, in the compression molding in the second step, the meat of the raw material first starts to move in the direction of low resistance, that is, toward the concave portion, and the movement of the meat toward the tip of the tooth portion is inspired by the movement. As a result, the material of the material is effectively applied to the shoulder portion of the tooth tip.

According to a fifth aspect of the present invention, there is provided the method of manufacturing a ring gear according to the fourth aspect, wherein the recess formed in the first step has a tapered inner wall surface. By making the inner wall surface of the concave portion tapered as described above, it is possible to perform the compression processing of the central portion of the material in the first step with a low load.

According to a sixth aspect of the present invention, there is provided an apparatus for manufacturing a ring gear from a plate-shaped material, wherein a gear trim mold mechanism for forming teeth on an outer peripheral portion of the material and a material serving as a center hole of the ring gear. A coining mold mechanism for compressing a central portion of the material to form a concave portion, a forming mold mechanism for compressing an outer peripheral portion of the material in a thickness direction thereof, and punching the center hole by punching a central portion of the material. And a piercing mold mechanism for molding. According to a seventh aspect of the present invention, there is provided the ring gear manufacturing apparatus according to the sixth aspect, wherein each of the mold mechanisms is driven by a general-purpose press.

[0011]

Embodiments of the present invention will be described below. First, a first embodiment will be described with reference to FIGS. FIG. 1 is a configuration diagram showing a ring gear material, and FIGS.
Is a block diagram showing the ring gear intermediate product in the order of the molding process, and FIG. 5 is a block diagram showing the finished ring gear. FIG. 1
5A to 5A are plan views and FIG. 5B is a cross-sectional view. The ring gear material 10 shown in FIG. 1 is a metal plate having a predetermined thickness. As a first step, a first intermediate product 12 having a tooth portion 13 on the outer periphery as shown in FIG. Molding. This first intermediate product 12
Is performed by a gear trim mold mechanism 30 shown in FIG.

As shown in FIG. 6A, a trim die 32 and a guide plate 36 in a gear trim mold mechanism 30 are provided.
The material 10 is clamped between. In this state, the trim punch 38 descends while pushing down the ejector 34, and the first intermediate product 12 is punched by the trim punch 38 and the trim die 32 as shown in FIG. 6B. After the punching, the trim punch 38 and the guide plate 36 are raised, and the first intermediate product 12 is pushed out of the trim die 32 by the ejector 34. When the material 10 is punched by the trim die 32 and the trim punch 38, the outer peripheral portion of the tooth portion 13 in the first intermediate product 12 as shown in FIG. (Tooth tip) has a shoulder drooping portion 13a.

As a next step, the second intermediate product 14 shown in FIG. 3 is formed from the first intermediate product 12 by the coining mold mechanism 40 shown in FIG. When the first intermediate product 12 is set in the coining mold mechanism 40, the front and back of the first intermediate product 12 are reversed from the state shown in FIG. 6 and the ejector 44 and the coining punch 48 of the coining mold mechanism 40 as shown in FIG. Clamp between. When the coining punch 48 descends while pushing down the ejector 44, the outer periphery (the tooth portion 13) of the first intermediate product 12 is restrained by the coining die 42 as shown in FIG. It becomes a bottomed state that cannot be lowered any more.

Further, the coining punch 48 is shown in FIG.
By descending to the state shown in (C), the central portion of the first intermediate product 12 is compressed between the coining punch 48 and the ejector 44. As a result, the second intermediate product 14 having the concave portion 16 at the center as shown in FIG. 3 is formed. After this molding, the coining punch 48 is raised, and the second intermediate product 14 is extruded from the coining die 42 by the ejector 44.

As described above, in the second intermediate product 14,
As the recess 16 is formed, the meat (material) in the central portion that is finally punched out and becomes the center hole 22 (FIG. 5) of the ring gear moves toward the outer peripheral portion. Therefore, the thickness of the outer peripheral portion of the second intermediate product 14 is increased, and its dimension is larger than the thickness of the finished product 20 shown in FIG. Further, as shown in FIG. 3 (B), the inner wall surface of the concave portion 16 of the second intermediate product 14 is set to have a tapered shape which is open upward, so that the compressive load by the coining punch 48 is small. Also, the first intermediate product 12 can be easily processed.

As a next step, a third intermediate product 18 shown in FIG. 4 is formed from the second intermediate product 14 by a forming mold mechanism 50 shown in FIG. When the second intermediate product 14 is set in the forming mold mechanism 50, as shown in FIG. 8 (A), the recess 16 is turned up and the ejector 54 of the forming mold mechanism 50 and the forming punch 58 are moved. Clamp. When the forming punch 58 is lowered while pushing down the ejector 54, the outer periphery (tooth portion 13) of the second intermediate product 14 is formed as shown in FIG.
2 and the ejector 54 is in a bottomed state where it cannot be further lowered.

Further, the forming punch 58 is shown in FIG.
By lowering to the state shown in (C), the second position between the forming punch 58 and the ejector 54 is reduced.
The outer peripheral portion of the intermediate product 14 is compressed until the thickness of the finished product 20 shown in FIG. 5 is reached, and the third intermediate product 18 is formed. After this forming, the forming intermediate 58 is pushed out from the forming die 52 by the ejector 54 while the forming punch 58 is raised.

By compressing the outer peripheral portion of the second intermediate product 14 as described above, the meat (material) of the outer peripheral portion starts to largely move toward the concave portion 16 and is inspired by this to cause the tooth portion 13 to move. The movement (shunting) of the meat toward the tip is promoted. As a result, the meat efficiently moves to the shoulder drooping portion 13a of the tooth tip where flow of the meat is unlikely to occur due to its shape, and the meat is applied to the shoulder drooping portion 13a. As a result,
As shown in FIG. 4B, the third intermediate product 18 has a highly accurate tooth portion 13 with no shoulder sag.

Here, an experiment was conducted in which two kinds of second intermediate products 14 having the same material and plate thickness as the raw material 10 but different in the space volume of the recess 16 were prepared, and the outer peripheral portions thereof were compressed with a constant load. went. As a result, as the space volume of the concave portion 16 is larger, the movement (shunting) of the meat toward the tip of the tooth portion 13 is further promoted, and the reduction rate of the droop height of the shoulder droop portion 13a at the tooth tip is larger. It was confirmed that a lower load was required even when the outer peripheral portion of the second intermediate product 14 was compressed. Therefore, by forming the concave portion 16 having a larger space volume than in the case of compressing a flat material, the meat of the material is moved efficiently and as intended toward the shoulder 13a of the tooth tip. Can be done.

As the last step, the finished product 20 shown in FIG. 5 is formed from the third intermediate product 18 by the piercing die mechanism 60 shown in FIG. At the time of this molding, as shown in FIG.
Clamp. Then, the guide plate 66 and the piercing punch 68 descend while pushing down the piercing die 62 and the ejector 64. As a result, FIG.
As shown in (B), the tooth portion 13 of the third intermediate product 18 is finished by the gear finishing die 63, and the outer periphery of the third intermediate product 18 is restrained inside the die 63. At this time, the pierce dice 62 is in a bottomed state in which it cannot be further lowered.

Further, as the piercing punch 68 descends while pushing down the ejector 64, FIG.
As shown in (C), the central portion of the third intermediate product 18 is punched out to form the center hole 22 of the ring gear. Thereafter, the guide plate 66 and the piercing punch 68 are raised, and the piercing dies 62 and the ejectors 64 are pushed up to push the finished product 20 out of the piercing dies 62 and the gear finishing dies 63 together with the punched portions (unnecessary portions). . As shown in FIG.
0 has a larger inner diameter than the trace of the concave portion 16 remaining in the third intermediate product 18, and therefore the concave portion 1
No trace of 6 remains on the finished product 20.

As described above, the coining mold mechanism 4 shown in FIG.
0, the meat (material) of the central portion of the first intermediate product 12 which is an unnecessary portion of the ring gear material is moved toward the outer peripheral portion, and the thickness of the outer peripheral portion of the second intermediate product 14 is larger than that of the finished product 20. Is realized.
Further, the outer peripheral portion of the second intermediate product 14 is compressed by the forming mold mechanism 50 in FIG. 8 to make the finished product 20 thicker, and the shoulder portion 13a of the tooth portion 13 is filled with the third intermediate product. The product 18 is produced, and the “second step” is realized in which the center portion of the third intermediate product 18 is punched out by the piercing mold mechanism 60 in FIG. The manufacture of the ring gear in the present embodiment is made up of the “first step” and the “second step”.

Next, a second embodiment will be described with reference to FIGS. FIG. 10 is a configuration diagram illustrating a ring gear material according to the second embodiment, and FIG. 11 is a configuration diagram illustrating a ring gear intermediate product. In FIGS. 10 and 11, (A) of each drawing shows a plan view, and (B) shows a sectional view. The finished ring gear is described in Embodiment 1.
Is the same as the finished product 20 (FIG. 5).

In the first step, the intermediate product 14A shown in FIG. 11 is formed from the raw material 10A shown in FIG. 10 by the coining mold mechanism 70 shown in FIG. First, FIG.
As shown in (A), the material 10A is clamped between the trim die 72 and the guide plate 76 in the coining mold mechanism 70. Next, as shown in FIG. 12B, when the punch 78 is lowered, the outer shape of the material 10A is formed by punching using the punch 78 and the trim die 72.

When the punch 78 is further lowered to the state shown in FIG. 12C, the central portion of the material 10A is compressed from below by the punch 78 and the coining die 74. As a result, an intermediate product 14A having a concave portion 16A at the center as shown in FIG. 11 is formed. After this molding, the punch 78 is raised, and the intermediate product 14A is pushed out of the trim die 72 by pushing up the coining die 74.

In the intermediate product 14A, as the recess 16A is formed, the center portion of the ring gear is formed into a central hole 22 (FIG. 5) by the center portion 22 (FIG. 5). Moving towards. Therefore, the thickness of the outer peripheral portion of the intermediate product 14A is increased, and its dimension is larger than the thickness of the finished product 20 shown in FIG.

As a next step, the finished product 20 shown in FIG. 5 is formed from the intermediate product 14A by the multi-die mechanism 80 shown in FIG. In this molding, as shown in FIG. 13A, between the gear die 82 and the guide plate 92, between the ejector 84 and the gear punch 90, and the piercing punch 88 in the multi-die mechanism 80.
Intermediate product 1 between the pierce ejector 94 and
Clamp 4A. 13B, the intermediate product 14A is clamped between the ejector 84 and the gear punch 90 and between the piercing punch 88 and the piercing ejector 94 while the gear punch 90 is clamped.
Lowers while pushing down the ejector 84 together with the first backup 96 and the second backup 97. At this time, the tooth portion 13 is formed on the outer periphery of the intermediate product 14A by the gear punch 90, and at the same time, a central portion to be the center hole 22 of the finished product 20 is punched by the piercing punch 88. The ejector 84 is a punch holder 86
It is in the bottomed state that was received by.

The gear die 82 and the gear punch 90
When the intermediate product 14 </ b> A is punched out by the above, due to the initial material retraction, the shoulder tip 1 similar to the first intermediate product 12 in the first embodiment is attached to the tip of the tooth portion 13.
3a has occurred. Thereafter, the gear punch 90 further descends, and as shown in FIG.
The outer peripheral portion of the intermediate product 14 </ b> A is compressed between the and the ejector 84 to form the finished product 20.

By compressing the outer peripheral portion of the intermediate product 14A in this manner, the flesh (material) of the outer peripheral portion starts to largely move toward the concave portion 16A, as in the first embodiment. The movement of the meat toward the tip of the tooth 13 also occurs. Therefore, the meat moves efficiently with respect to the shoulder drooping portion 13a of the tooth portion 13, and the meat is applied to this shoulder drooping portion 13a. For this reason, also in the present embodiment, the finished product 20 having the high-precision tooth portion 13 without shoulder sag is formed.

In the second embodiment, the meat (material) of the central portion of the material 10A, which is an unnecessary portion of the ring gear material, is moved toward the outer peripheral portion by the coining mold mechanism 70 of FIG. The "first step" of producing the intermediate product 14A having a thickness larger than that of the finished product 20 is realized.
Further, the intermediate product 14 is provided by the multi-die mechanism 80 shown in FIG.
The outer peripheral portion of A is subjected to compression processing to make the finished product 20 thicker,
In addition, the shoulder 13a of the tooth portion 13 is filled with meat, and the middle portion of the intermediate product 14A is punched to complete the finished product 2.
The “second step” in which the center hole 22 is 0 is realized.

That is, the multi-die mechanism 80 in the second embodiment is different from the gear-trim mold mechanism 3 in the first embodiment.
0, forming mold mechanism 50 and piercing mold mechanism 6
It has zero functions. Therefore, in Embodiment 2,
The number of man-hours for changing the material (intermediate product) can be reduced while reducing the number of mold mechanisms. Each of the mold mechanisms 30, 40, 50, 60, and 7 in the first and second embodiments.
0 and 80 are each driven by a general-purpose press machine, and do not require special equipment.

While the preferred embodiment of the present invention has been described with reference to the drawings, this embodiment can be easily modified or modified without departing from the spirit of the present invention. For example, there is a type of the ring gear which is the above-mentioned finished product 20, which has a tooth portion on an inner periphery thereof. In order to form a ring gear of this type on the basis of the process of the first embodiment, first, a first intermediate product 1 having a tooth portion on the inner periphery is used.
The meat of the outer peripheral part (unnecessary part) of No. 2 is moved toward the central part. As a result, a second intermediate product 14 having a larger thickness at the central portion than the finished product 20 is produced. Next, the central portion of the second intermediate product 14 is subjected to compression processing to complete the finished product 20.
The third intermediate product 18 is made by making the thickness of the inner peripheral teeth thicker and applying the flesh to the shoulder droop of the inner peripheral teeth. Finally, the outer peripheral portion of the third intermediate product 18 is punched out and finished to a predetermined outer diameter to obtain a finished product 20.

Even in the case of a ring gear having teeth on the inner periphery as described above, the outer peripheral portion (unnecessary portion) finally removed from the raw material 10 is compressed to reduce the thickness of the unnecessary portion. It is moved toward the central part (required part), and the required part is compressed to fill the shoulder droop with meat. Note that it is of course possible to form a ring gear of this type based on the process of the second embodiment.

[Brief description of the drawings]

FIG. 1 is a configuration diagram showing a ring gear material.

FIG. 2 is a configuration diagram showing a ring gear intermediate product in a first molding step.

FIG. 3 is a configuration diagram showing a ring gear intermediate product in a next molding step.

FIG. 4 is a configuration diagram showing a ring gear intermediate product in a next molding step.

FIG. 5 is a configuration diagram showing a completed ring gear product.

FIG. 6 is a cross-sectional view illustrating a processing state by a gear trim mold mechanism.

FIG. 7 is a sectional view showing a processing state by a coining mold mechanism.

FIG. 8 is a cross-sectional view illustrating a processing state by a forming mold mechanism.

FIG. 9 is a cross-sectional view showing a processing state by a piercing die mechanism.

FIG. 10 is a configuration diagram showing a ring gear material according to a second embodiment.

FIG. 11 is a configuration diagram showing a ring gear intermediate product according to the second embodiment;

FIG. 12 is a cross-sectional view illustrating a processing state by the coining mold mechanism according to the second embodiment.

FIG. 13 is a cross-sectional view illustrating a processing state by the multi-die mechanism according to the second embodiment.

[Explanation of symbols]

 10, 1A material 13 Tooth 16, 16A recess 20 Finished product 22 Center hole

Claims (7)

[Claims] 1. A method of manufacturing a ring gear in which an unnecessary portion of a raw material which does not affect the function of a manufactured product is moved toward a required portion of the manufactured product. 2. The unnecessary portion which is finally removed from the material is compressed to move the meat of the unnecessary portion toward another necessary portion, and the thickness of the necessary portion is larger than that of the finished product. A method of manufacturing a ring gear, comprising: a first step of producing an intermediate product; and a second step of compressing the required portion to a thickness of a finished product and cutting and removing the unnecessary portion. 3. In a material for manufacturing a ring gear, a central portion which is finally punched out and becomes a center hole of the ring gear is subjected to compression processing, so that the thickness of the central portion is reduced to the outer periphery of the material which becomes a tooth portion of the ring gear. Move towards the part,
A first step of producing an intermediate product in which the thickness of the outer peripheral portion is larger than that of the finished product; compressing the outer peripheral portion to make the finished product thicker; and punching out the central portion to form the center hole. And a second step of forming the ring gear. 4. The method of manufacturing a ring gear according to claim 3, wherein in the first step, a concave portion is formed by compressing a central portion of the material, and in the second step, A method of manufacturing a ring gear in which the outer peripheral portion of the material on which the tooth portion is formed is subjected to compression processing to make the finished product thicker, thereby moving the outer peripheral portion of the material to the concave portion and the tip of the tooth portion. 5. The method according to claim 4, wherein the recess formed in the first step has a tapered inner wall surface. 6. An apparatus for manufacturing a ring gear from a plate-shaped material, comprising: a gear trim mold mechanism for forming a tooth portion on an outer peripheral portion of the material; and a compression processing of a central portion of the material to be a center hole of the ring gear. A coining mold mechanism for forming a concave portion, a forming mold mechanism for compressing an outer peripheral portion of the material in a thickness direction thereof, and a piercing mold mechanism for punching a central portion of the material to form the center hole. A ring gear manufacturing device comprising: 7. The ring gear manufacturing apparatus according to claim 6, wherein each of the mold mechanisms is driven by a general-purpose press.