JP3711890B2 - Gear rolling method and rolling apparatus - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a gear rolling method and a rolling device, and more particularly to a gear rolling method and a rolling device that create a tooth profile by meshing and rotating a tooth-forming roller and a disk-shaped workpiece. .
[0002]
[Prior art and problems to be solved by the invention]
In the rolling of gears by the generating rolling method, for example, as described in Japanese Patent Application Laid-Open No. 11-347474, one of the gear meshing relationships is a gear-shaped tooth forming roller (tooth profile roller die). Using the other as a disk-shaped workpiece, the workpiece supported by a predetermined mandrel and the tooth forming roller are rotated synchronously, and a feed is applied in a direction to reduce the distance between the axes, thereby creating a tooth profile on the workpiece. It is based on that.
[0003]
Since the surplus part (burr) is inevitably generated with the progress of tooth profile creation, the technique described in the above publication turns the surplus part simultaneously with tooth profile creation or with a bite following tooth profile creation. However, in order to completely remove the surplus part by turning, the bite must be cut more than the thickness of the surplus part, and even a part of the mandrel supporting the workpiece should be removed. In order to prevent this, it is necessary to make the mandrel have a split movable structure or a stepped shape as described in the publication, and the mandrel cost must be increased. It is not preferable.
[0004]
Therefore, instead of cutting the surplus part with the above-mentioned cutting tool, the above-mentioned surplus part is cut and removed with a mandrel by using a special cutting roller, so that the surplus part is cut off. The present applicant has also proposed a technique which can be performed by roll forming, for example, as Japanese Patent Application No. 2000-168354.
[0005]
In this technique, referring to FIG. 2 showing the embodiment of the present invention, the tooth profile G is rolled by meshing the tooth forming roller 3 and the workpiece W wider than the tooth width dimension of the tooth profile G to be molded. In doing so, both side surfaces of the tooth profile G are constrained by a backup roller (not shown) for backing up the forming force, and when the end of rolling is reached, the cutting roller is used instead of the tooth forming roller 3 or together with the tooth forming roller 3 22 is pressed against the workpiece W, and the surplus portions formed on both side surfaces of the tooth profile G are cut by the push-off method.
[0006]
[Problems to be solved by the invention]
However, if the tooth side of the tooth profile G is constrained by the backup roller from the beginning to the end of the rolling process as described above, a part of the surplus portion flows into the tooth bottom side particularly at the end of rolling. This is allowed and driven in, and the tooth bottom surface is in a so-called loose state. If the workpiece after the completion of rolling is subjected to a heat treatment, the cracking starting from the above-mentioned peeling portion is generated, which is not preferable because the original strength of the gear is lowered.
[0007]
In addition, if rolling is performed without constraining the tooth side surface of the tooth profile G, the tooth profile G is unnecessarily widened in the tooth width direction, and the cutting process of the tooth side surface in the subsequent process is indispensable. It will be done.
[0008]
The present invention has been made paying attention to the above-mentioned problems, and on the premise that it is a rolling technique that even performs the removal of the surplus part, driving the surplus part to the tooth profile side that was created in particular. It is an object of the present invention to provide a rolling method and a rolling device that prevent the occurrence of a stagnation state.
[0009]
[Means for Solving the Problems]
According to the first aspect of the present invention, as described above, one of the gear meshing relations is a gear-shaped tooth forming roller and the other is a disk-shaped workpiece, and the workpiece is a pair of mandrels. It is premised on the rolling method of the gear that is formed in such a manner that the tooth profile is formed on the workpiece by feeding in a direction that reduces the distance between the shaft centers while being rotated synchronously with the tooth forming roller.
[0010]
Then, a backup roller is pressed against the workpiece together with the tooth forming roller, and each of these rollers is rotated synchronously with the workpiece, so that the forming force generated by the tooth forming roller is backed up by the backup roller and the surplus generated on the side surface of the generating tooth profile. The process of creating a tooth profile by crushing the part, and pressing the cutting roller between the mandrel and the mandrel by pressing the cutting roller against the workpiece and rotating synchronously at the end of the tooth profile creation. When the tooth profile is created, the tooth side surfaces at both ends in the tooth width direction of the creation tooth profile are pressed and restrained by a backup roller, while the surplus portion is pushed by the cutting roller. The pressure restraint of the tooth side surfaces at both ends in the tooth width direction of the generating tooth profile is released.
[0011]
As the above-described cutting roller, for example, a sharp push-out nose portion is formed in a portion that directly controls the removal operation of the surplus portion of the cut roller, and the diameter of the push-out nose portion is set to the diameter of the general portion of the cut roller. It is desirable to set it slightly smaller than.
[0012]
Further, the removal of the surplus portion may be performed after the tooth profile is created, but it is desirable that the removal is performed in parallel with the tooth profile creation in order to shorten the total machining time.
[0013]
Therefore, according to the first aspect of the present invention, although both sides (tooth side surfaces) of the generating tooth are positively restrained by the backup roller from the initial stage to the middle stage of the tooth profile rolling, the end stage of the tooth profile generation is reached. When pressing the surplus part with the cutting roller, if the pressure restraining force on the tooth side is released, the surplus part generated on the tooth side will not be driven into the tooth side of the generating tooth shape. The meat part is cut and removed by a so-called push-cut action between the mandrel and the cutting roller.
[0014]
A second aspect of the present invention is a gear rolling device that captures the technique according to the first aspect as a gear rolling device, and has a tooth forming roller having a tooth profile generating portion wider than the tooth width dimension of the tooth profile to be generated; The tooth forming roller is disposed so as to face the tooth forming roller with the workpiece interposed therebetween, and is pressed against the workpiece together with the tooth forming roller to rotate synchronously with the workpiece, thereby backing up the forming force of the tooth forming roller. A backup roller that crushes the surplus portion that occurs on the side surface, and a cutting roller that presses against the workpiece at the end of tooth profile creation and synchronously rotates the surplus portion that is crushed by the backup roller with the mandrel It has.
[0015]
The backup roller includes a tooth profile restriction groove that pressurizes and constrains the tooth side surfaces at both ends of the tooth width direction of the creation tooth profile while receiving the tooth profile at the time of tooth profile creation, and a surplus portion is formed by the cutting roller. A clearance groove is formed that receives the tooth profile at the time of pushing, but is not in contact with the tooth side surfaces at both ends in the width direction of the tooth profile. It is characterized by being possible.
[0016]
In this case, as in the third aspect of the invention, the tooth-shaped constraining grooves and the relief grooves are arranged in parallel on the outer peripheral surface of the backup roller, and these tooth-shaped constraining grooves are formed by a shift operation in the axial direction of the backup roller. It is desirable to be able to selectively switch between and the escape groove.
[0017]
Therefore, in the inventions according to the second and third aspects of the present invention, the tooth profile restraining groove of the backup roller is matched with the generating tooth profile from the initial stage to the middle period of the tooth profile rolling, and the generating tooth profile is positively maintained while backing up the tooth forming force. The tooth side surface is pressed and restrained, and the shape accuracy of the generating tooth profile is increased.
[0018]
On the other hand, if the end of the tooth profile rolling has been reached, the backup roller is once separated from the generating tooth profile before the cutting of the surplus portion by the cutting roller is started, and the above operation is performed by the shift operation in the axial direction of the backup roller. After the groove to be matched with the generating tooth profile is switched from the tooth-shaped constraining groove to the relief groove, the relief groove is again matched with the creation tooth profile. In this case, although the original function of the backup roller is exhibited, the escape groove maintains a non-contact state with respect to the tooth side surface of the generating tooth profile and does not exert any pressure restraining force. As a result, the tooth side surface of the generating tooth profile is unconstrained, and the surplus portion generated on the tooth side surface is not driven into the bottom surface side of the generating tooth shape, and the surplus portion is pushed between the mandrel and the cutting roller. It is cut off by the action.
[0019]
【The invention's effect】
According to the invention described in claim 1, until the end of the tooth profile rolling process, rolling is performed while restraining the tooth side surface of the created tooth profile under pressure, but if the end of the tooth profile rolling is reached, Since the pressurizing restraint force is positively released and the surplus portion is cut and removed in the unrestrained state, the surplus portion is not driven into the root surface of the generating tooth shape as in the past. In addition to improving the accuracy and strength of the generating tooth profile, the generating tooth profile does not spread beyond the width of the tooth more than necessary, and the excess part is reliably cut and removed, so that it is possible to eliminate the cutting process in the subsequent process. .
[0020]
According to the second and third aspects of the invention, since the technique of the first aspect is embodied as a rolling device, the same effect as that of the first aspect of the invention can be obtained. As long as there is a shift function of the roller, the intended purpose can be achieved, and there is an advantage that simplification of the structure can be achieved as a rolling device having a function of cutting and removing the surplus portion.
[0021]
DETAILED DESCRIPTION OF THE INVENTION
1 and the following drawings show a preferred embodiment of a gear rolling device according to the present invention, and particularly FIGS. 1 and 2 show a schematic structure of a main part of the device.
[0022]
As shown in FIGS. 1 and 2, the disk-shaped workpiece W to be processed is subjected to a thickening process in advance so that the peripheral edge thereof is thick, and a rim portion R is formed. The part R is offset in the left or right direction with respect to the general part of the workpiece W as shown in FIGS. The workpiece W is held by a pair of left and right mandrels 1 and 2 arranged so as to be positioned on the same axis, and the workpiece W is rotated together with the mandrels 1 and 2 by a rotation driving means (not shown). It has become.
[0023]
A spur gear-shaped tooth-forming roller (tooth-shaped roller die) 3 and a backup roller 4 are disposed opposite to each other with the workpiece W supported by the mandrels 1 and 2 interposed therebetween. The tooth-forming roller 3 is rotatably supported by a roller holder 6 with an axis 5 parallel to the mandrels 1 and 2, while the backup roller 4 is also rotated to a roller holder 8 via an axis 7 parallel to the mandrels 1 and 2. The tooth forming roller 3 is formed with a tooth profile 9 that is a reference tooth profile (tooth profile generating section) that is sufficiently wider than the rim R, and is formed on the cylindrical outer peripheral surface of the backup roller 4. As shown in FIGS. 3 and 4, an annular tooth-shaped restraining groove 10 having a trapezoidal cross section for receiving the rim portion R of the workpiece W and an annular relief groove 11 having a rectangular cross section are formed adjacent to each other. .
[0024]
Then, the tooth forming roller 3 is brought into pressure contact with the work W and the backup roller 4 is brought into pressure contact with the mandrels 1, 2 and W, respectively, and the tooth forming roller 3 and the backup roller 4 are synchronously rotated together with the work W supported by the mandrels 1, 2. In addition, by pushing the tooth forming roller 3 toward the workpiece axis from the radial direction, the tooth forming portion 9 on the tooth forming roller 3 side is transferred to the rim portion R of the work W, and the tooth shape G is created.
[0025]
The mandrels 1 and 2 supporting the workpiece W and the tooth forming roller 3 are rotationally driven mechanically and synchronously by a rotation driving means (not shown), and come into pressure contact with the mandrels 1 and 2 or the workpiece W. The backup roller 4 is driven to follow the rotation of the mandrels 1 and 2 or the workpiece W.
[0026]
The tooth-shaped restraining groove 10 and the relief groove 11 formed on the backup roller 4 are not used at the same time, and the rim portion R is moved by shifting the backup roller 4 by a predetermined amount in the axial direction. The position can be selectively switched for use. Then, as shown in FIG. 3, when the tooth shape restraining groove 10 is selected and the mandrels 1, 2 and the work W are backed up, the tooth shape restraining groove 10 receives the rim portion R, so that the inner side surface is the work W side. 4 is set so as to press and restrain both side surfaces (tooth side surfaces) in the tooth width direction of the tooth profile G, while selecting the relief groove 11 as shown in FIG. Is backed up, the clearance groove 11 receives the rim portion R, but a gap C of a predetermined amount (for example, about 2 mm at the maximum) is secured between the inner side surface and both side surfaces of the tooth profile G on the workpiece W side. Thus, the relief groove 11 is set so as not to directly contact the created tooth profile G, that is, the relief groove 11 on the backup roller 4 side does not exert any pressure restraining force on the tooth profile G.
[0027]
Here, the slide drive system of the backup roller 4 will be described with reference to FIGS. 5 to 8. The roller holder 8 supporting the backup roller 4 is fixed to the slider 13 by the clamper 12 and the slider 13. Is guided and supported by the guide way 14 via a linear guide (not shown) so as to be movable forward and backward. A pressure cylinder (for example, a hydraulic cylinder) 15 is attached to the guide way 14, and a piston rod 16 of the pressure cylinder 15 is connected to the slider 13. Accordingly, the back-up roller 4 is moved forward by the stroke S together with the slider 13 by the extension operation of the pressure cylinder 15, and is pressed against the mandrels 1, 2 or the workpiece W as described above.
[0028]
On the other hand, the guide way 14 is mounted on a shift slider 17, and the shift slider 17 is slidably guided and supported on a base 19 via a linear guide 18. A shift cylinder (for example, a hydraulic cylinder) 20 is mounted on the base 19 side, and a piston rod 21 of the shift cylinder 20 is connected to the shift slider 17. Accordingly, the backup roller 4 is slid by a predetermined stroke in the axial direction of the backup roller 4 together with the shift slider 17 in accordance with the expansion / contraction operation of the shift cylinder 20, and with this, the tooth-shaped restraining groove 10 and the relief groove 11 in the backup roller 4. Is switched.
[0029]
As shown in FIGS. 1 and 2, the pair of cutting rollers 22 face each other across the work W supported by the mandrels 1 and 2 so as not to interfere with the tooth forming roller 3 and the backup roller 4. Is arranged. Each of these cutting rollers 22 is provided for cutting and removing the surplus portions B (see FIGS. 3 and 4) generated on both side surfaces of the rim portion R in accordance with the tooth profile creation. 22 is rotatably supported by a roller holder 24 through a shaft 23 parallel to the mandrels 1 and 2, and thrust is applied by a hydraulic cylinder (not shown) as in the case of the backup roller 4 described above. The tooth forming roller 3 and the backup roller 4 are in contact with the workpiece W or the mandrels 1 and 2 and rotate in synchronization with the workpiece W.
[0030]
As shown in FIG. 9, an annular groove 25 having a slightly larger cross-sectional shape than the rim portion R is formed on the cylindrical outer peripheral surface of the cutting roller 22 to receive the rim portion R. As will be described later, a relatively sharp push-cut nose portion 26 having a minimal rounded chamfer for pushing off the surplus portion B generated along with the generation of the tooth profile is projected on both sides of 25, and the push-cut nose. On both sides of the portion 26, relief grooves 27 having a circular arc cross section for receiving the surplus portion B are formed.
[0031]
Here, as shown in FIG. 10, the diameter of the push-nose nose 26 is smaller than that of the general surface of the cutting roller 2 so that the push-nose nose 26 of the cutting roller 22 does not directly interfere with the mandrels 1 and 2. Is also formed small in advance, for example, by about 0.02 mm so as to be reduced by a predetermined amount a.
[0032]
Therefore, according to the rolling device of the present embodiment, as shown in FIG. 3 and FIG. 11 (A), the tooth-shaped constraining groove is formed at a position corresponding to the workpiece W by using the shift function of the backup roller 4 described above. 10 is determined. Then, when the tooth forming roller 3 and the backup roller 4 are pressed against the workpiece W supported by the mandrels 1 and 2 while being synchronously rotated, the workpiece W as shown in FIG. 3 and FIG. Since the rim portion R on the side is received in the tooth shape restriction groove 10 of the backup roller 4 and both side surfaces (tooth side surfaces) of the rim portion R are pressure restricted on the inner side surface of the tooth shape restriction groove 10, The tooth profile 9 of the tooth forming roller 3 is engaged with the rim R of W and the shape is transferred to create a tooth profile G.
[0033]
In the process of tooth profile creation by rolling, forward rotation and reverse rotation of the workpiece W are periodically repeated as necessary, and both side surfaces of the rim portion R are provided with the tooth profile restraining grooves of the backup roller 4 as described above. 110, the surplus portion (burr) B generated with the creation of the tooth profile enters the gap between the backup roller 4 and the mandrels 1 and 2 as shown in FIG. It is crushed thinly by the backup roller 4.
[0034]
When the end of the tooth profile creation by the tooth forming roller 3 is reached, the backup roller 4 is temporarily retracted during the synchronous rotation of the mandrels 1 and 2 and the tooth forming roller 3 as shown in FIG. The groove is switched by using the shift function of the backup roller 4 as shown in FIG. That is, the backup roller 4 is shifted in the axial direction, and the escape groove 11 is indexed at a position corresponding to the rim portion R on the workpiece W side instead of the tooth-shaped restraint groove 10 so far. Then, the backup roller 4 is advanced again and pressed against the mandrels 1 and 2 as shown in FIG.
[0035]
Before and after the switching operation of the groove on the backup roller 4 side, the pair of cutting rollers 22 are also pressed against the mandrels 1 and 2 to rotate synchronously with the workpiece W as shown in FIGS. . As a result, as shown in FIG. 9, the pushing nose portion 26 bites into the base portion of the surplus portion B thinned first by the backup roller 4, and a force that pushes off the surplus portion B by the cut-off action acts. To do. As a result, the surplus portion B generated with the tooth profile creation is cut and removed from the root portion with the rotation of the workpiece W as described above.
[0036]
At this time, the relief groove 11 of the backup roller 4 pressed against the mandrels 1 and 2 receives the rim portion R on the workpiece W side as shown in FIG. Since it is set in advance, no pressure restraining force is exerted on the tooth side surface of the rim portion R, and only the root portion of the surplus portion B is merely pressure restrained. Therefore, there is no possibility that a part of the surplus portion B is driven into the tooth bottom side of the tooth profile G just created after the end of the tooth profile creation as in the prior art.
[0037]
Note that the tooth forming roller 3 may be separated from the tooth profile G created by retracting the tooth forming roller 3 at the same time as the cutting roller 22 is operated as described above. However, in order to improve the accuracy of the tooth profile G, the tooth forming roller 3 is used. Is still kept in mesh with the tooth profile G.
[0038]
Here, as described above, in order to avoid direct interference between the mandrels 1 and 2 and the relatively sharp push-cut nose portion 26 of the cutting roller 122, the diameter of the push-cut nose portion 26 is set to its general surface. Is set to be about 0.02 mm smaller than that, and the minimum push-off dimension of the surplus portion B is also about 0.02 mm, but the surplus portion B has a thickness at the base portion of about 0.02 mm. By the time, it is surely separated from the workpiece W.
[0039]
At the same time, the cutting roller 22 faithfully follows the shape of the surplus portion B due to the cushion function of a hydraulic cylinder or the like and exhibits its push-off effect, and at the same time, chipping of the relatively sharp push-cut nose 26 is prevented. The
[0040]
As described above, according to the present embodiment, it is assumed that the backup roller 4 and the cutting roller 22 are used in addition to the tooth forming roller 3, and if the end of the tooth profile generation is reached, the backup roller is used until then. Since the pressure restraining force 4 exerted on the tooth side surface of the rim portion R is released, the surplus portion B generated thereby is cut and removed in a short time without using a bite at the same time as the tooth profile creation. In addition, the surplus portion B is not driven into the root surface side of the tooth profile G just created.
[Brief description of the drawings]
FIG. 1 is an explanatory diagram of a main part configuration showing a preferred embodiment of a gear rolling device according to the present invention.
2 is an explanatory cross-sectional view taken along line AA in FIG.
FIG. 3 is an enlarged cross-sectional view of a main part showing a relationship between a workpiece and a backup roller during tooth profile rolling.
FIG. 4 is an enlarged cross-sectional view of the main part showing the relationship between the work and the backup roller at the end of the tooth profile rolling.
FIG. 5 is an explanatory plan view showing a support form of the backup roller shown in FIG. 1;
6 is an explanatory diagram on the right side of FIG. 5;
7 is an explanatory diagram on the right side of FIG. 6;
8 is an explanatory cross-sectional view taken along the line DD in FIG. 6;
FIG. 9 is an enlarged cross-sectional view of the main part showing the relationship between the workpiece and the cutting roller at the end of the tooth profile rolling.
10 is an enlarged view of a Q part in FIG. 9;
FIG. 11 is a process explanatory view showing a series of procedures for tooth profile rolling.
[Explanation of symbols]
1, 2 ... Mandrel 3 ... Tooth forming roller 4 ... Backup roller 10 ... Tooth shape restraining groove 11 ... Relief groove 22 ... Cutting roller 26 ... Push-off nose part B ... Surplus part G ... Tooth form R ... Rim part W ... Workpiece

Claims (3)

One of the gear meshing relations is a gear-shaped tooth forming roller and the other is a disk-shaped work, and the shaft between the two is rotated synchronously with the tooth forming roller after the work is sandwiched between a pair of mandrels. A method of rolling a gear by creating a tooth profile on a workpiece by feeding in a direction to reduce the distance between the centers,
A backup roller is pressed against the workpiece together with the above-mentioned tooth forming roller, and each of these rollers is rotated synchronously with the workpiece, so that a surplus portion generated on the side surface of the generating tooth shape is backed up while the forming force by the tooth forming roller is backed up by the backup roller. Crushing and creating a tooth profile;
A step of pressing the surplus portion crushed by the backup roller between the mandrel by pressing the cutting roller in contact with the workpiece at the end of the tooth profile creation and rotating synchronously;
Including
When generating the tooth profile, the tooth side surfaces at both ends in the tooth width direction of the generating tooth profile are pressed and restrained with a backup roller, while when the surplus portion is pushed by the cutting roller, the tooth width of the generating tooth profile is A method of rolling a gear, wherein the pressure restraint on the tooth side surfaces at both ends in the direction is released. One of the gear meshing relations is a gear-shaped tooth forming roller and the other is a disk-shaped work, and the shaft between the two is rotated synchronously with the tooth forming roller after the work is sandwiched between a pair of mandrels. A gear rolling device that creates a tooth profile on a workpiece by feeding in a direction to reduce the distance between the centers,
A tooth forming roller having a tooth profile generating portion wider than the tooth width dimension of the tooth profile to be generated;
The side surface of the generating tooth profile is arranged so as to face the tooth forming roller with the workpiece interposed therebetween, and presses the workpiece together with the tooth forming roller and rotates synchronously with the workpiece to back up the forming force by the tooth forming roller. A backup roller that crushes the surplus portion that occurs in the
A cutting roller that presses the surplus portion crushed by the backup roller with the mandrel by synchronously rotating in contact with the workpiece at the end of tooth profile creation;
With
The back-up roller includes a tooth-form restricting groove that pressurizes and constrains the tooth side surfaces at both ends in the width direction of the tooth while receiving the tooth form when the tooth form is created, and the cutting roller pushes off the surplus portion. When the tooth profile is received, clearance grooves that are in non-contact with the tooth side surfaces at both ends in the width direction of the tooth profile are formed, and these tooth profile restraining grooves and clearance grooves are selectively used. A gear rolling device characterized in that it is possible. The tooth profile restraining groove and the relief groove are arranged in parallel on the outer peripheral surface of the backup roller, and the tooth profile restraining groove and the relief groove can be selectively switched by a shift operation in the axial direction of the backup roller. The gear rolling device according to claim 2.

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