JP5135837B2 - Gear rolling method and rolling apparatus - Google Patents

Description

  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 in which a tooth shape is created by meshing and rotating a roller die and a disk-shaped workpiece. It is about.

  2. Description of the Related Art Conventionally, a gear rolling method and a rolling device have been proposed in which a tooth shape is created by meshing and rotating a roller die and a disk-shaped workpiece (see Patent Document 1).

This is because the roller die having a plurality of rolled teeth on the outer peripheral portion is pressed into the outer peripheral portion of the workpiece at a predetermined pressing speed while rotating synchronously with respect to the disk-shaped workpiece. This is a gear rolling method in which a gear-shaped member is rolled by rolling the outer periphery of the disk-shaped workpiece with teeth. In order to shorten the cycle time and prolong the tool life, first, the intermediate-stage rolled teeth are created by a roller die having a processing tooth having a pressure angle larger than the desired pressure angle of the completed tooth profile. Next, the finished teeth and the involute tooth surface of the rolled teeth are outlined by a roller die provided with processed teeth having a desired pressure angle of the finished tooth shape on the rolled teeth created in the first step. And a second step consisting of an intermediate step to create and a finishing step to finish and create the involute tooth surface of the rolled tooth including the tooth tip.
JP 2006-917 A

  However, in the above-described conventional example, as a finishing process of the second process, the involute tooth surface and the tooth tip of the rolling tooth are created by a roller die having a finished tooth shape having a desired pressure angle. As a result, the machined teeth of the roller die have a high height and are easily chipped. As a result, the tool life is short, and the generation load cannot be increased (low molding load resistance), so the generation cycle time There was a problem that it became longer.

  Accordingly, the present invention has been made in view of the above problems, and an object of the present invention is to provide a gear rolling method and a rolling apparatus suitable for improving the roller die life and shortening the molding cycle time.

According to the present invention, a roller die having a plurality of processed teeth to be rolled on the outer peripheral portion is synchronously rotated with respect to a disk-shaped workpiece and pressed into the outer peripheral portion of the workpiece at a predetermined pressing speed. In a rolling method and a rolling device of a gear for rolling a gear-shaped member by rolling the outer periphery of the disk-shaped workpiece with processed teeth, a pressure angle larger than a desired pressure angle of a completed tooth profile A first step of creating an intermediate-stage rolled tooth by a roller die provided with a processed tooth, and a rolled tooth created in the first step of a root shape and a completed tooth shape that do not contact the tip of the rolled tooth. A roller die having a processed tooth formed in a tooth surface shape and a tooth tip shape of a desired pressure angle is pressed against the tooth bottom and tooth surface of the rolled tooth to create the tooth bottom and tooth surface of the rolled tooth. and 2 step, the rolling teeth were created in the second step, the tooth surfaces of the rolling tooth A third step of creating the addendum of the rolling tooth by a roller die having a forming teeth of creating the tooth tip area of the finished tooth profile in contact only the addendum of the rolling tooth without contacting the tooth bottom and And so on.

Therefore, in the present invention, as the completed tooth profile forming step, the tooth profile of the desired pressure angle of the root shape and the completed tooth profile that do not contact the tooth tip of the rolled tooth and the rolled tooth created in the first step, and In the second and second steps, a roller die having processed teeth formed in a tooth tip shape is pressed against the root and tooth surface of the rolled tooth to create the bottom and tooth surface of the rolled tooth. A roller die having a processed tooth that creates a tooth tip region of a complete tooth profile by contacting only the tooth tip of the rolled tooth without contacting the tooth surface and the tooth bottom of the rolled tooth. The third step of creating the tooth tip of the rolled tooth by dividing the root / tooth surface processing and the tooth tip processing to reduce the molding load of each step, and the roller die, particularly the third step Can improve the life of roller dies and shorten the cycle time of tooth profile It can be.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, a gear rolling method and a rolling apparatus according to an embodiment of the invention will be described with reference to FIGS. FIG. 1 is a process diagram for explaining each process of gear production including a gear rolling method of the present embodiment, FIG. 2 is a schematic diagram of a gear rolling apparatus of the present embodiment, and FIGS. 3 to 5 are roller dies. FIG. 6 to FIG. 8 are explanatory views of tooth profiles showing the rolling process of gears.

  In FIG. 1, in the gear manufacturing method of the present embodiment, as shown in step (A), a blank W is first manufactured by punching a thick steel plate into a circle. Next, as shown in the step (B), the thickness of the other portions except for the outer peripheral portion of the blank W and the mounting boss portion (not shown) is subjected to coining with a step forming machine made of a press to reduce the thickness. Further, as shown in step (C), the outer peripheral portion is crushed by a thickening molding machine consisting of a spinning machine to increase the thickness of the outer peripheral portion so that the tooth profile can be rolled to form the rim portion W1, and the gear rolling is performed. Get possible gear material. In step (D), a roller die is pressed against the outer periphery of the rim portion W1 of the gear material obtained in step (C), and both are synchronously rotated to create a rolling tooth profile on the outer periphery of the rim portion W1 of the gear material. . Further, in step (E), machining of the chamfer surface of the gear is performed to complete the gear. This chamfer surface processing is added when the rolled gear is not used in a constantly meshed state but is slid only when necessary to mesh with another gear, for example, when used for an engine starter gear or the like. The

  As shown in FIG. 2, the gear rolling device in the step (D) is rotated by a pair of mandrels 1A and 1B that function as main shafts for holding and rotating the workpiece W while holding the workpiece W, and mandrels 1A and 1B. The roller die 2 that creates the rolling teeth W2 on the outer periphery of the workpiece W by pressing the processing teeth 3A to 3C on the outer periphery of the workpiece W while rotating synchronously with the workpiece W as a gear material, and the mandrel 1A at a position facing the roller die 2 1B is provided with a side restraint roller 4 that regulates the protrusion in the width direction of the rolling teeth W2 created on the outer periphery of the work W while rotating in contact with the outer periphery of 1B.

  The mandrels 1A and 1B are arranged so as to be positioned on the same axis so as to hold and hold the disk-shaped workpiece W to be processed in a state where the rim portion W1 is fitted to the tip of one mandrel 1A. And a pair of main shafts 1 are provided. The pair of main shafts 1 are arranged so as to be able to advance and retreat in the axial direction, the work W can be attached and detached by opening the tips apart from each other, and the work W can be held under pressure by approaching each other. The workpiece W is driven to rotate by being driven to rotate.

  The roller die 2 is held so as to rotate together with the shaft 5 on a shaft 5 parallel to the main shaft 1 of the mandrels 1A and 1B, and has processing teeth 3A to 3C on the outer peripheral portion. The shaft 5 is configured to rotate in synchronism with the main shaft 1 of the mandrels 1A and 1B and be movable in the approaching and detaching direction with respect to the main shaft 1, and the processing teeth 3A to 3C of the roller die 2 are moved by approaching the main shaft 1. Is pressed against the outer periphery of the workpiece W to plastically deform the outer periphery of the workpiece W so as to create the rolling teeth W2 on the outer periphery of the workpiece W. The roller die 2 is fixedly disposed on the shaft in the order of a rough die 2A, a tooth bottom / tooth surface finishing die 2B, and a tooth tip finishing die 2C, and is moved laterally (in the axial direction) for each generating step. The die 2A is used by switching from the tooth bottom / tooth surface finishing die 2B and the tooth tip finishing die 2C. Each of the dice 2A to 2C has a width sufficiently larger than the width of the rim portion W1 of the workpiece W.

  The rough die 2A performs processing with a relatively high degree of processing to create a basic shape of a tooth profile on the outer periphery of the workpiece W, and performs processing with the highest rolling load applied to the processing teeth 3A. Therefore, as shown in FIG. 3, the processed tooth 3A has a relatively large pressure angle (also called a tooth right angle pressure angle or wedge angle), an arc-shaped tooth tip, and a relatively narrow tooth bottom. It is formed to have a chevron-shaped tooth profile having a large tooth root thickness. In this way, the chevron shaped tooth 3A having a large tooth root thickness and a relatively large pressure angle has a function of phase matching between the workpiece W to be machined and the roller die 2, and is pushed into the outer periphery of the workpiece W at the time of creation. It can be made to have high strength against bending load that sometimes occurs, and exhibits high durability. In addition, the arc-shaped tooth tip makes good familiarity with the rolling teeth W2 formed on the workpiece W so that the rolling teeth W2 are not turned up. The pressure angle is set by deriving an appropriate angle in advance from a trial experiment or the like so that an internal defect such as a turn-up scratch does not occur inside the rolled tooth W2 of the created work W.

  The root / tooth surface finishing die 2B is modified with respect to the rolling tooth W2 created on the outer periphery of the workpiece W by the rough die 2A, and the profile of the tooth bottom W3 / involute tooth surface W4 of the rolling tooth W2 is modified. To decide. For this reason, as shown in FIG. 4, the processed tooth 3B has a pressure angle for the formed rolled tooth to form the same pressure angle as the product shape, and the widths of the tooth tip and the tooth base are enlarged. It is provided as an arc shape, and the involute tooth surface W4 and tooth root width of the rolled tooth W2 created on the outer periphery of the workpiece W are formed in the same shape as the product shape. The tooth bottom of this processed tooth 3B is opposed to the portion corresponding to the tip of the rolled tooth W2, but is formed in a shape that escapes the tip of the rolled tooth W2, and the tooth of the rolled tooth W2 is created at the time of creation. It does not create a tip shape. The rolled tooth profile created by the rough die 2A on the outer periphery of the workpiece W is widened at the bottom of the tooth by the bottom / tooth surface finishing die 2B, and the surplus wall is pushed out to the involute tooth surface W4 and the tooth tip to form the involute tooth surface W4. And it correct | amends so that the tooth-tip W5 may be expanded.

  In the tooth tip finishing die 2C, the tip of the rolled tooth W2 created by the bottom / tooth surface finishing die 2B is subjected to final correction and the tooth tip portion connected to the involute tooth surface W4 is the same as the product shape. It is to make a shape. For this reason, as shown in FIG. 5, the processed tooth 3C has the same shape as the tooth tip portion of the product shape to be created, although the tooth shape and the tooth bottom are interchanged with the product shape. The involute tooth surface W4 is formed with a low tooth height so as to mesh only at a slight size on the tip side. In the illustrated example, the shape of the bottom surface of the processed tooth 3C is remarkably changed so that the tip of the rolled tooth W2 is made flatter.

  The side restraint roller 4 is disposed so as to contact the outer periphery of the mandrels 1A and 1B at a position facing the roller die 2 so as to be rotated along with the mandrels 1A and 1B, and is applied to the workpiece W from the roller die 2. The load is received together with the main shaft 1. A circumferential groove 4A formed to have the same width as the rim portion W1 of the rolling gear W is provided on the outer periphery of the side restraint roller 4, and the workpiece W is engaged by engaging the circumferential groove 4A with the rim portion W1 on the outer periphery of the workpiece W. When a rolling tooth profile is created on the rim portion W1 by the roller die 2, it functions to adjust the rim shape of the workpiece W by returning to the rim portion W1 the surplus that protrudes in the width direction of the rolling tooth profile.

  A gear rolling method using the gear rolling device having the above configuration will be described below.

  First, between the left and right mandrels 1A, 1B of the rolling device, the rim portion W1 of the gear material formed in the step (C) is fitted to either one of the mandrels 1A, and the left and right mandrels 1A, 1B is advanced, and the inner peripheral side of the rim portion W1 is clamped by the tips of the mandrels 1A and 1B to hold the workpiece W. Next, the outer periphery of the side restraint roller 4 is pressed against the outer periphery of the mandrels 1A and 1B by aligning the axial positions of the circumferential groove 4A of the side restraint roller 4 and the rim W1 of the work W held by the mandrels 1A and 1B. The rim W1 of the workpiece W is fitted into the circumferential groove 4A of the side restraint roller 4.

  Next, the mandrels 1A and 1B are driven to rotate. The work W held by the rotation of the mandrels 1A and 1B is rotated, and the side restraint roller 4 in contact with the mandrels 1A and 1B is also rotated. The rim portion W1 of the work W rotates while part of the rim portion W1 enters the circumferential groove 4A of the side restraint roller 4.

  Next, the roller die 2 is axially aligned so that the processing teeth 3A of the rough die 2A overlap the rim portion W1 of the workpiece W, and the rough die 2A is pushed to the outer periphery of the rim portion W1 of the workpiece W as shown in FIG. Push it in. The outer periphery of the rim portion W1 is recessed at the portion where the outer periphery engages with the processing teeth 3A by meshing with the processing teeth 3A of the rough die 2A, and the surplus thickness is raised and created at the remaining portion.

  In the initial stage of pressing, the contact between the processing teeth 3A and the workpiece W is intermittently performed, so that the rolling load is intermittently generated and vibration is likely to occur. It is desirable to transition to contact. Further, the rolling process to the outer periphery of the rim portion W1 by the processing teeth 3A is accompanied by protrusion of the surplus thickness to the side (axial direction) of the rim portion W1. When engaged with the circumferential groove 4A, the circumferential groove 4A is pushed back into the rim portion W1.

  Pushing is performed at the stage where the pushing amount of the rough die 2A reaches the specified position (the stage where the pitch circle of the processing tooth 3A and the pitch circle of the rolled gear created on the workpiece W are rotating in contact with each other). When the roller die 2 is stopped and then separated from the workpiece W, the outer periphery of the rim portion W1 created by the rough die 2A has the same contour as the processing teeth 3A of the rough die 2A as shown in FIG. The rolled teeth W2 are formed (transferred).

  Next, the roller die 2 is aligned in the axial direction so that the processing teeth 3B of the tooth bottom / tooth surface finishing die 2B of the roller die 2 overlap the rim W1 of the workpiece W, and the tooth bottom / tooth surface finishing die 2B is moved to the workpiece. Press against the outer periphery of the rim W1 of W and push it in. The tooth tip of the processing tooth 3B of the bottom / tooth surface finishing die 2B is the tooth bottom W3 of the rolling tooth W2 on the outer periphery of the rim W1, and the tooth base of the processing tooth 3B is the tooth of the rolling tooth W2 on the outer periphery of the rim W1. Engage with W5.

  Further, when the bottom / tooth surface finishing die 2B is pushed in, the tooth tip of the processed tooth 3B bites into the bottom portion of the rolled tooth W2 on the outer periphery of the rim portion W1 to enlarge the bottom W3 and the surplus of the rim. The rolled tooth W2 on the outer periphery of W1 is raised to the tooth tip W5 side, and the tooth tip W5 is thickened. Further, the surplus protrusion that protrudes to the side (axial direction) of the rim portion W1 due to the rolling process by the processing teeth 3B is caused by the circumferential groove 4A when the rim portion W1 engages with the circumferential groove 4A of the side restraint roller 4. The rim portion W1 is pushed back inward.

  Then, the indentation amount of the bottom / tooth surface finishing die 2B in which the pitch circle (not shown) of the processing tooth 2B and the pitch circle (not shown) of the rolled tooth W2 created on the workpiece W come into contact with each other and rotates is defined. At the stage of reaching the position, the bottom W3 of the rolling tooth W2 on the outer periphery of the rim W1 is depressed to a predetermined amount, and the bottom W3 of the rolling tooth W2 is formed in the same shape as the product shape. The At the same time, the surplus that protrudes due to the formation of the recess that is the bottom W3 becomes extra to form the involute tooth surface shape of the involute tooth surface W4 of the rolled tooth W2 and to form the involute tooth surface shape. The surplus meat protrudes from the tooth tip of the rolled tooth W2, and the tooth tip W5 is thickened to a preset thickness. Further, the tip of the tooth tip W5 of the rolled tooth W2 formed by the rough die 2A is also crushed and pushed back by the tooth bottom of the processed tooth 3B of the tooth bottom / tooth surface finishing die 2B, and a new tooth is added together with the surplus. The tip W5 is formed.

  At this stage, when the pressing is stopped and then the roller die 2 is separated from the workpiece W, the bottom of the rim W1 created by the bottom / tooth surface finishing die 2B is shown in FIG. -Rolled teeth W2 having the same contour as the processed teeth 3B of the tooth surface finishing die 2B are formed (transferred). The obtained rolled tooth W2 has a gear shape including a tooth bottom W3 having the same shape as the product shape and an involute tooth surface W4 except for the shape of the tooth tip W5 portion. The tooth tip W5 of the obtained rolled tooth W2 is formed so that its shape does not match the product shape, but only its volume matches the volume of the product-shaped tooth tip W5.

  In this creation process, when the pressure angle of the processing teeth 3A of the rough die 2A deviates from an appropriate pressure angle to a small side or deviates to a large side, the processing teeth 3B of the bottom / tooth surface finishing die 2B are used. When the rolled tooth W2 is created, the surface portion of the rolled tooth W2 is located inside the tooth surface W4 at the boundary portion between the involute tooth surface W4 region and the tooth bottom region and the boundary portion between the involute tooth surface W4 region and the tooth tip W5 region. It turns into a so-called “turn-up wound” internal defect, which causes tooth surface peeling when used as a gear. Therefore, the pressure angle of the processing teeth 3A of the rough die 2A needs to be set in advance by a trial experiment or the like so that an appropriate angle that does not cause an internal defect such as a turn-up wound inside the rolled tooth W2 of the workpiece W created. is there.

  Next, the roller die 2 is aligned in the axial direction so that the processing teeth 3C of the tooth tip finishing die 2C of the roller die 2 overlap the rim portion W1 of the workpiece W, and the tooth tip finishing die 2C is positioned on the outer periphery of the rim portion W1 of the workpiece W. Press it down and push it in. Further, when the tooth tip finishing die 2C is pushed in, the shape of the tooth tip W5 portion of the rolled tooth W2 on the outer periphery of the rim W1 is corrected by the bottom of the processed tooth 3C, and the tooth tip W5 is formed. Further, the surplus protrusion that protrudes to the side (axial direction) of the rim portion W1 due to the rolling process by the processing teeth 3C is caused by the circumferential groove 4A when the rim portion W1 engages with the circumferential groove 4A of the side restraint roller 4. The rim portion W1 is pushed back inward.

  And the position where the pushing amount of the tooth tip finishing die 2C in which the pitch circle (not shown) of the processing tooth 3C and the pitch circle (not shown) of the rolling tooth W2 created on the workpiece W are in contact with each other and rotates is defined. In this stage, the tooth tip W5 of the rolling tooth W2 on the outer periphery of the rim portion W1 is expanded to a predetermined width and becomes a preset tooth tip width. At this stage, when the pushing is stopped and then the roller die 2 is separated from the workpiece W, the processing teeth 3C of the finishing die 2C are formed on the outer periphery of the rim portion W1 created by the finishing die 2C as shown in FIG. Are formed (transferred).

  By the way, in the creation process by the tooth tip finishing die 2C, as shown in FIG. 9, an outer periphery shake detection sensor 10 for detecting a radial deflection amount of the outer peripheral tooth tip surface of the rolled tooth W2 to be processed is provided. At the same time, the controller 11 can adjust the pressing position of the tooth finish finishing die 2 </ b> C provided with the processing teeth 3 </ b> C of the roller die 2 with respect to the rolling teeth W <b> 2 based on the detection value from the outer periphery shake detection sensor 10.

  That is, in the region where the outer peripheral diameter of the rolled tooth W2 is large, the pressing position of the tooth tip finishing die 2C is retracted up to the difference in which the outer peripheral diameter is increased, and in the region where the outer peripheral diameter of the rolled tooth W2 is small, the tooth tip is The pressing position of the finish tip die 2C is adjusted so that the pressing position of the finishing die 2C is advanced with the difference between the outer peripheral diameters being reduced. Incidentally, the control of the pressing position of the addendum finishing die 2C corresponds to the deviation between the detected angle position and the creation angle position by the addendum finishing die 2C (in the illustrated example, an angle slightly smaller than 180 degrees). Is rotated to reach the forming part, the position of the roller die 2 is changed based on the outer peripheral runout amount of the rolling teeth W2 so that the forming amount becomes constant.

  In this way, in the creation process by the tooth tip finishing die 2C, the pressing position of the tooth tip finishing die 2C is not pressed uniformly in the circumferential direction until reaching the position according to the preset pitch circle. Fine adjustment is performed within the allowable range of the radial dimension of the increased teeth W2. That is, the forming amount to the rolled tooth W2 by the tooth tip finishing die 2C is adjusted to be constant.

  For example, in the region where the outer peripheral diameter of the rolled tooth W2 is large, when pressing uniformly in the circumferential direction until reaching a position according to a preset pitch circle, the creation processing of the tooth tip finishing die 2C is performed, as shown in FIG. As shown in FIG. 4, the shape of the involute tooth surface W4 connected to the tooth tip surface of the rolled tooth W2 swells from the original involute shape, and a gear shape with good shape accuracy cannot be obtained.

  However, the shape of the involute tooth surface W4 connected to the inner peripheral side of the rolled tooth W2 is changed to the product shape (the root / involute) by making the forming amount by the tip finish die 2C uniform in the circumferential direction as described above. It is possible to prevent deformation from being affected by the amount of molding at the time of molding the tooth tip shape from the state of the molding shape by the tooth surface finishing die 2B. For this reason, a gear shape with good shape accuracy can be obtained.

  In the present embodiment, the following effects can be achieved.

(A) The roller die 2 having a plurality of processed teeth 3A to 3C for rolling on the outer peripheral portion is pushed into the outer peripheral portion of the workpiece W at a predetermined pushing speed while being synchronously rotated with respect to the disk-shaped workpiece W. Thus, when the gear-shaped member is rolled by rolling the outer periphery of the disk-shaped workpiece W with the processing teeth 3 of the roller die 2, a processing with a pressure angle larger than the desired pressure angle of the completed tooth profile is performed. A first step of creating an intermediate-stage rolled tooth W2 by a roller die 2A having teeth 3A, and a tooth base that does not contact the tip of the rolled tooth W2 on the rolled tooth W2 created in the first step A roller die 2B including a processing tooth 3B formed in a tooth surface shape and a tooth tip shape of a desired pressure angle of the shape and the completed tooth shape is pressed against the tooth bottom and tooth surface of the rolled tooth W2 to form the rolled tooth W2. A second step of creating a tooth bottom W3 and a tooth surface W4; Was created in rolling teeth W2 in step, the tooth tip W5 region of the finished tooth profile in contact only addendum W5 of the rolling tooth W2 without the tooth surface W4 and tooth gap W3 of the rolling tooth W2 contacts And a third step of creating a tooth tip W5 of the rolled tooth W2 by a roller die 2C provided with a processing tooth 3C. For this reason, the tooth bottom / tooth surface processing and the tooth tip processing are divided to reduce the molding load of each process, and the life of the roller die 2, especially the roller die 2C of the third process can be improved, and the tooth profile molding cycle Time can be shortened.

  (B) The tooth tip generating die 3C, which is a roller die in the third step, is reduced in production cost because the tooth height is set mainly to engage with the tooth tip region of the rolled tooth W2. And the tool life can be improved.

  (C) Tooth tip creation, which is the third step, is an outer periphery constituted by the tooth tip W5 of the rolled tooth W2 in which the tooth bottom W3 and the tooth surface W4 are created by the tooth bottom / tooth surface creation die 2B which is the second step. The deformation of the involute tooth surface W4 of the rolling tooth W2 can be suppressed by adjusting the roller die position according to the radial deflection of the rolling tooth and making the forming amount of the rolling tooth W2 uniform in the circumferential direction. A gear part with high shape accuracy can be manufactured.

Process drawing explaining each process of gear manufacture including the rolling method of the gear which shows one Embodiment of this invention. The schematic of the rolling device of the gear of this embodiment similarly. The front view which shows the shape of the rough processing tooth | gear of a roller die. The front view which shows the shape of the processing tooth which creates the tooth root and tooth surface of a roller die. The front view which shows the shape of the process tooth which creates the tooth tip of a roller die. The front view which shows the shape of the rolling tooth created by the rough processing tooth. The front view which shows the shape of the rolling tooth created by the processing tooth of a tooth base and a tooth surface. The front view which shows the shape of the rolling tooth created by the processed tooth of the tooth tip. Explanatory drawing which shows the creation method by the processed tooth of a tooth tip. Explanatory drawing which shows the deformation | transformation state of the tooth surface at the time of increasing the shaping | molding load by the process tooth of a tooth tip.

Explanation of symbols

W Work W1 Rim part W2 Rolled teeth 1 Spindle 1A, 1B Mandrel 2 Roller die 2A Coarse die (roller die in the first step)
2B Bottom / tooth surface finish dies (roller dies in the second step)
2C Tooth tip finishing dies (roller dies in the second step)
3A-3C Processing teeth 4 Side restraint roller 4A Circumferential groove

Claims (7)

By rolling a roller die having a plurality of processing teeth for rolling on the outer peripheral portion synchronously rotating with respect to the disk-shaped workpiece and pushing it into the outer peripheral portion of the workpiece at a predetermined pressing speed, the circular teeth are processed with the processing teeth of the roller die. In the rolling method of the gear that performs rolling on the outer periphery of the plate-shaped workpiece and rolls the gear-shaped member,
First, a first step of creating an intermediate-stage rolled tooth by a roller die provided with a processed tooth having a pressure angle larger than a desired pressure angle of the completed tooth profile;
Next, processed teeth formed into a tooth shape that is not in contact with the tooth tip of the rolled tooth and a tooth surface shape and a tooth tip shape of a desired pressure angle of the finished tooth shape are formed on the rolled tooth created in the first step. A second step in which the roller die provided is pressed against the root and tooth surface of the rolled tooth to create the bottom and tooth surface of the rolled tooth;
Next, the rolled tooth created in the second step is brought into contact with only the tooth tip of the rolled tooth without contacting the tooth surface and the tooth bottom of the rolled tooth, thereby creating a tooth tip region of the complete tooth profile. And a third step of creating a tooth tip of the rolled tooth with a roller die provided with the machining teeth.   2. The gear rolling method according to claim 1, wherein the roller die of the third step is set to have a tooth height so as to mainly engage with a tooth tip region of the rolling tooth. 3.   In the third step, the roller die position is adjusted according to the radial runout of the outer periphery formed by the tooth tip of the rolled tooth created in the second step, and the forming amount of the rolled tooth in the circumferential direction is adjusted. The method of rolling a gear according to claim 1 or 2, wherein the method is uniform.   The processing tooth of the roller die in the first step includes a chevron-shaped tooth profile having a large tooth root thickness by an arc-shaped tooth tip and a relatively narrow tooth bottom. The gear rolling method as described in one. The processing teeth of the roller die in the second step following the first step have a tooth profile that is arcuate by expanding the width of the tip and bottom of the processing teeth of the roller die in the first step,
The rolling of the gear according to any one of claims 1 to 4, wherein the tooth bottom of the rolled tooth in the first step is expanded to push the surplus back to the tooth tip. Method.   The surplus generated in the axial direction of the rolling teeth when creating the rolling teeth on the disk-shaped workpiece rotates in contact with the mandrel holding the workpiece or the workpiece in rotation at a position facing the roller die. The gear rolling according to any one of claims 1 to 5, wherein the side surface of the work outer periphery is engaged with a side wall of a circumferential groove provided on the side surface constraining roller to restrain the pressure. Method. A roller die having a plurality of processed teeth to be rolled on the outer periphery is rotated into a disk-shaped workpiece sandwiched between a pair of mandrels while being synchronously rotated into the outer periphery of the workpiece at a predetermined pressing speed. It is a gear rolling device that performs rolling on the outer peripheral portion of the disk-shaped workpiece with a die processing tooth,
It is arranged so as to face the roller die across the workpiece, and rotates with the roller die in pressure contact with the workpiece to back up the rolling load by the roller die and to remove the surplus generated on the side surface of the rolling tooth profile. A side restraint roller that is pushed back by the side wall of the groove;
A rough generating die for creating intermediate-stage rolled teeth with a processed tooth having a pressure angle larger than the desired pressure angle of the finished tooth profile, a root shape that does not contact the tip of the rolled tooth, and a desired tooth profile shape . Tooth base and tooth surface that have processed teeth formed into pressure angle tooth surface shape and tooth tip shape, and modify the root shape and tooth surface shape of the rolled tooth to create the root and tooth surface of the complete tooth shape A generating die, and a processed tooth that creates a tooth tip region of a complete tooth profile by contacting only the tooth tip of the rolled tooth without contacting the tooth surface and the tooth bottom of the rolled tooth; A gear rolling device comprising: a roller die that can be switched to a tooth tip generating die that corrects a tooth tip of a rolled tooth created by a tooth surface generating die.