JP6927469B1 - How to manufacture ring gears and pinion gears - Google Patents

How to manufacture ring gears and pinion gears Download PDF

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JP6927469B1
JP6927469B1 JP2020201038A JP2020201038A JP6927469B1 JP 6927469 B1 JP6927469 B1 JP 6927469B1 JP 2020201038 A JP2020201038 A JP 2020201038A JP 2020201038 A JP2020201038 A JP 2020201038A JP 6927469 B1 JP6927469 B1 JP 6927469B1
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shaped portion
shaft
disk
gear
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浩之 毛利
浩之 毛利
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株式会社コタニ
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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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J13/00—Details of machines for forging, pressing, or hammering
    • B21J13/02—Dies or mountings therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/02—Die forging; Trimming by making use of special dies ; Punching during forging
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/20—Recycling

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  • Mechanical Engineering (AREA)
  • Forging (AREA)

Abstract

【課題】従来のリングギヤの製造方法でスクラップとして廃棄していた中央部分を活用して別部品を製造することで廃材を出さないようにする。【解決手段】本発明に係るリングギヤとピニオンギヤの製造方法は、円柱状の素材１００を熱間据込鍛造することにより、リングギヤ１４２の荒地としての円盤状部分１３０ｂと、当該円盤状部分の中心部から軸線方向片側方向に延びたピニオンギヤ１４７の荒地としての軸状部分１３０ａとを有する中間材１３０を成形する第１工程と、円盤状部分と軸状部分の周方向境界断面（切り離し線１４０ｃ）を上下型でプレスして薄肉化する第２工程と、軸状部分を軸線方向片側方向に押圧することにより、当該軸状部分を円盤状部分から切り離す第３工程と、を有することを特徴とする。【選択図】図１PROBLEM TO BE SOLVED: To prevent waste material from being generated by manufacturing another part by utilizing a central portion which has been discarded as scrap in a conventional ring gear manufacturing method. SOLUTION: In the method for manufacturing a ring gear and a pinion gear according to the present invention, a cylindrical material 100 is hot-installed and forged to form a disk-shaped portion 130b as a rough ground of the ring gear 142 and a central portion of the disk-shaped portion. The first step of forming an intermediate material 130 having a shaft-shaped portion 130a as a rough ground of a pinion gear 147 extending in one side in the axial direction from the above, and a circumferential boundary cross section (separation line 140c) between the disk-shaped portion and the shaft-shaped portion. It is characterized by having a second step of pressing with a vertical die to thin the wall, and a third step of separating the shaft-shaped portion from the disk-shaped portion by pressing the shaft-shaped portion in one side in the axial direction. .. [Selection diagram] Fig. 1

Description

本発明は、鍛造により１つの素材からリングギヤとピニオンギヤを同時に製造する製造方法に関するものである。 The present invention relates to a manufacturing method for simultaneously manufacturing a ring gear and a pinion gear from one material by forging.

従来、自動車のデファレンシャルなどに使用されるリングギヤは、鍛造により製造されている。図４は従来の鍛造による製造方法の概略を示したもので、（ａ）は鍛造により成形したリングギヤの第１中間材（荒地）２４０である。この第１中間材２４０は、外周部のリング状部分２４０ａと中心部の円盤状部分２４０ｂとを有する。 Conventionally, ring gears used for automobile differentials and the like are manufactured by forging. FIG. 4 shows an outline of a conventional manufacturing method by forging, in which (a) is a first intermediate material (rough ground) 240 of a ring gear formed by forging. The first intermediate member 240 has a ring-shaped portion 240a at the outer peripheral portion and a disk-shaped portion 240b at the central portion.

円盤状部分２４０ｂは周方向に延びる破線部２４０ｃで切り離して図４（ｄ）のようにスクラップ２４６として廃棄していた。円盤状部分２４０ｂを切り離したリング状部分２４０ａを第２中間材２４１として、図４（ｃ）のようにローリング（圧延）により仕上加工してギヤ粗材２４２にしていた。 The disk-shaped portion 240b was separated by a broken line portion 240c extending in the circumferential direction and discarded as scrap 246 as shown in FIG. 4 (d). The ring-shaped portion 240a from which the disk-shaped portion 240b was separated was used as the second intermediate material 241 and finished by rolling as shown in FIG. 4 (c) to obtain a gear rough material 242.

ギヤ粗材２４２の外周面は、ホブ切りによりはすば歯車が切削加工された後、表面硬化処理工程で浸炭焼入れを施される。これで目的とするディファレンシャル用リングギヤが製造される。なお、以下の特許文献１〜３には１つの素材から２部品（軸受内外輪）を同時に製造する製造方法が記載されている。 The outer peripheral surface of the gear rough material 242 is carburized and hardened in a surface hardening treatment step after the helical gear is cut by hobbing. This manufactures the desired differential ring gear. The following Patent Documents 1 to 3 describe a manufacturing method for simultaneously manufacturing two parts (bearing inner and outer rings) from one material.

特開昭５９−１８３９４８号公報JP-A-59-183948 特開平１１−２４４９８５号公報Japanese Unexamined Patent Publication No. 11-244985 特開２０１３−２４０８１９号公報Japanese Unexamined Patent Publication No. 2013-240819

従来のリングギヤの製造方法は、中央の円盤状部分２４０ｂをスクラップ２４６として廃棄するので材料が無駄になる。そこで本発明の目的は、従来のリングギヤの製造方法でスクラップとして廃棄していた中央部分を活用して別部品を製造することで、廃材を出さないようにすることにある。 In the conventional ring gear manufacturing method, the central disk-shaped portion 240b is discarded as scrap 246, so that the material is wasted. Therefore, an object of the present invention is to manufacture another part by utilizing the central portion that has been discarded as scrap in the conventional ring gear manufacturing method, so that no waste material is generated.

前記課題を解決するため、本発明のリングギヤとピニオンギヤの製造方法は、円柱状の素材を熱間据込鍛造することにより、リングギヤの荒地としての円盤状部分と、当該円盤状部分の中心部から軸線方向片側方向に延びたピニオンギヤの荒地としての軸状部分とを有する中間材を成形する第１工程と、前記円盤状部分と前記軸状部分の周方向境界断面を上下型でプレスして薄肉化する第２工程と、前記軸状部分を軸線方向片側方向に押圧することにより、当該軸状部分を前記円盤状部分から切り離す第３工程と、を有することを特徴とする。 In order to solve the above problems, in the method for manufacturing a ring gear and a pinion gear of the present invention, a columnar material is hot-installed and forged from a disk-shaped portion as a rough ground of the ring gear and a central portion of the disk-shaped portion. The first step of forming an intermediate material having a shaft-shaped portion as a rough ground of a pinion gear extending in one side in the axial direction, and a thin wall by pressing the circumferential boundary cross section of the disk-shaped portion and the shaft-shaped portion with an upper and lower mold. It is characterized by having a second step of forging and a third step of separating the shaft-shaped portion from the disk-shaped portion by pressing the shaft-shaped portion in one side in the axial direction.

本発明は、従来のリングギヤの製造方法でスクラップとして廃棄していた中央部分を活用してピニオンギヤを製造することで、廃材を出さないようにすることができる。 According to the present invention, the pinion gear can be manufactured by utilizing the central portion that has been discarded as scrap in the conventional ring gear manufacturing method, so that no waste material is generated.

リングギヤとピニオンギヤの製造方法の概略を示すもので、（ａ）リングギヤとピニオンギヤの中間材の断面図、（ｂ）リングギヤ荒地の断面図、（ｃ）リングギヤの製品断面図、（ｄ）ピニオンギヤ荒地の断面図、（ｅ）ピニオンギヤの製品断面図である。The outline of the manufacturing method of the ring gear and the pinion gear is shown. Cross-sectional view, (e) is a product cross-sectional view of a pinion gear. 素材の変形を工程順に示す断面図である。It is sectional drawing which shows the deformation of a material in the order of a process. リングギヤとピニオンギヤの製造に使用する上型と下型を工程順に示す断面図である。It is sectional drawing which shows the upper die and the lower die used for manufacturing a ring gear and a pinion gear in the order of a process. 円盤状部分と軸状部分の軸方向連続位置の違いによる切り離し性への影響を示す図である。It is a figure which shows the influence on the separability by the difference in the axial continuous position of a disk-shaped part and a shaft-shaped part. 従来のリングギヤの製造方法の概略を示すもので、（ａ）リングギヤの第１中間材の断面図、（ｂ）リングギヤの第２中間材の断面図、（ｃ）リングギヤの製品断面図、（ｄ）スクラップの断面図である。The outline of the conventional method for manufacturing a ring gear is shown. ) It is a cross-sectional view of scrap.

以下、本発明に係るリングギヤとピニオンギヤの製造方法の一実施形態を図面に基づいて説明する。図１は、本発明に係る製造方法の概略を示すもので、（ａ）はリングギヤの荒地としての円盤状部分１４０ｂと、ピニオンギヤの荒地としての軸状部分１４０ａを含む第１中間材１４０の断面図である。この第１中間材１４０から、図１（ｃ）のリングギヤ１４２と（ｅ）のピニオンギヤ１４７をそれぞれ製作することができる。 Hereinafter, an embodiment of a method for manufacturing a ring gear and a pinion gear according to the present invention will be described with reference to the drawings. FIG. 1 shows an outline of the manufacturing method according to the present invention, in which (a) is a cross section of a first intermediate material 140 including a disk-shaped portion 140b as a rough ground of a ring gear and a shaft-shaped portion 140a as a rough ground of a pinion gear. It is a figure. From this first intermediate material 140, the ring gear 142 of FIG. 1 (c) and the pinion gear 147 of (e) can be manufactured, respectively.

すなわち、第１中間材１４０を図１（ｂ）と（ｄ）のように切り離して、第２中間材１４１、１４６を得る。これら第２中間材１４１、１４６をローリング（圧延）やホブ切りなどの機械加工をすることにより、リングギヤ１４２とピニオンギヤ１４７を製作することができる。 That is, the first intermediate material 140 is separated as shown in FIGS. 1 (b) and 1 (d) to obtain the second intermediate materials 141 and 146. The ring gear 142 and the pinion gear 147 can be manufactured by machining the second intermediate materials 141 and 146 such as rolling and hobbing.

（工程の流れ）
図２Ａは製造方法の工程の流れに沿って素材の変形を工程順に示す断面図である。０工程は加工前の円柱状の素材１００である。ここでは外径が８０ｍｍ、軸長が１６０ｍｍの素材１００を使用する。なお、本願発明の説明上使用する寸法（ｍｍ）や比率（％）等はすべて例示であって、それらの寸法や比率等に限定する趣旨ではないことをここで明確にしておく。 (Process flow)
FIG. 2A is a cross-sectional view showing the deformation of the material in the order of the steps along the flow of the steps of the manufacturing method. Step 0 is the columnar material 100 before processing. Here, a material 100 having an outer diameter of 80 mm and a shaft length of 160 mm is used. It should be clarified here that the dimensions (mm), ratio (%), etc. used in the description of the present invention are all examples and are not intended to be limited to those dimensions, ratios, etc.

この素材１００を最初の１工程の熱間据込み鍛造で上下方向に圧縮し、外径１１５ｍｍ、軸長１０５ｍｍの鍛造品１１０を成形する。この場合、軸長と外径の比（軸長／外径）は９１％である。この比率は、鍛造品１１０の大きさによって例えば８０〜１２０％の範囲内で変更することができる。 This material 100 is compressed in the vertical direction by hot stationary forging in the first step to form a forged product 110 having an outer diameter of 115 mm and a shaft length of 105 mm. In this case, the ratio of the shaft length to the outer diameter (shaft length / outer diameter) is 91%. This ratio can be changed, for example, in the range of 80 to 120% depending on the size of the forged product 110.

次に、この鍛造品１１０を（ｃ）の２工程で下向きに押出し成形して軸状部分１２０ａを有する第１荒地１２０を成形する。続いて、（ｄ）の３工程で軸状部分１３０ａの基端側を上下方向にプレスして拡径することにより、円盤状部分１３０ｂを有する第２荒地１３０を成形する。この３工程において、（ｃ）の軸状部分１２０ａを（ｄ）の軸状部分１３０ａのように製品形状に近付ける。 Next, the forged product 110 is extruded downward in the two steps (c) to form a first wasteland 120 having a shaft-shaped portion 120a. Subsequently, in the three steps (d), the base end side of the shaft-shaped portion 130a is pressed in the vertical direction to increase the diameter, thereby forming the second wasteland 130 having the disc-shaped portion 130b. In these three steps, the shaft-shaped portion 120a of (c) is brought closer to the product shape like the shaft-shaped portion 130a of (d).

ここで、軸状部分１２０ａを成形した後に円盤状部分１３０ｂを成形する理由は、逆に成形すると軸心部分の材料ボリュームが不足するためである。軸心部分の材料ボリュームが不足すると、軸状部分１２０ａの先端部まで材料が充足されない可能性がある。 Here, the reason for molding the disc-shaped portion 130b after molding the shaft-shaped portion 120a is that the material volume of the shaft-shaped portion is insufficient when the shaft-shaped portion 120a is molded in reverse. If the material volume of the axial portion is insufficient, the material may not be filled up to the tip of the axial portion 120a.

但し、第２荒地１３０の円盤状部分１３０ｂの外径が比較的小さく、これに対して軸状部分１２０ａの軸長が比較的短い場合は、円盤状部分１３０ｂを成形した後に軸状部分１２０ａ、１３０ａを成形することも可能である。このように成形順を逆にしても、軸心部分の材料ボリュームが不足せず、したがって軸状部分１２０ａの先端部まで材料を充足することができるからである。 However, when the outer diameter of the disk-shaped portion 130b of the second wasteland 130 is relatively small and the shaft length of the shaft-shaped portion 120a is relatively short, the shaft-shaped portion 120a, after molding the disk-shaped portion 130b, It is also possible to mold 130a. This is because even if the molding order is reversed in this way, the material volume of the axial center portion is not insufficient, and therefore the material can be filled up to the tip end portion of the axial portion 120a.

（ｅ）の４工程は、（ｄ）の第２荒地１３０の軸状部分１３０ａと円盤状部分１３０ｂをさらに製品形状に近付けると共に、軸状部分１３０ａと円盤状部分１３０ｂの周方向境界断面を薄肉化するものである。すなわち、（ｄ）の第２荒地１３０の形状では、軸状部分１３０ａと円盤状部分１３０ｂの周方向境界断面が厚すぎるため、１つの切り離し工程で両者を分離するのが困難である。 In the four steps (e), the shaft-shaped portion 130a and the disc-shaped portion 130b of the second wasteland 130 of (d) are further brought closer to the product shape, and the circumferential boundary cross section of the shaft-shaped portion 130a and the disc-shaped portion 130b is thinned. It is something that becomes. That is, in the shape of the second wasteland 130 in (d), since the circumferential boundary cross section of the shaft-shaped portion 130a and the disk-shaped portion 130b is too thick, it is difficult to separate the two in one separation step.

そこで本発明の製造方法では、（ｄ）の第２荒地１３０の軸状部分１３０ａと円盤状部分１３０ｂの周方向境界断面を（ｅ）の４工程で薄肉化してから両者を切り離すことにした。詳しくは、（ｄ）の円盤状部分１３０ｂの上面に高さが異なる同心状の環状段差面１４０ｄ、１４０ｅを形成する。 Therefore, in the manufacturing method of the present invention, the circumferential boundary cross section of the axial portion 130a and the disc-shaped portion 130b of the second wasteland 130 (d) is thinned in the four steps of (e), and then the two are separated from each other. Specifically, concentric annular stepped surfaces 140d and 140e having different heights are formed on the upper surface of the disk-shaped portion 130b of (d).

高い方の段差面１４０ｄから低い方の段差面１４０ｅにかけて下り傾斜となる。一方、円盤状部分１４０ｂのほぼ水平な下面１４０ｆは軸状部分１４０ａの外径面に対してほぼ直角で接続している。 A downward slope is formed from the higher step surface 140d to the lower step surface 140e. On the other hand, the substantially horizontal lower surface 140f of the disk-shaped portion 140b is connected to the outer diameter surface of the shaft-shaped portion 140a at a substantially right angle.

そこで、軸状部分１４０ａを軸線方向下方にプレスすることで、前記下り傾斜の下端部を起点とし、軸状部分１４０ａの外径面に延びる切り離し線１４０ｃに沿って、軸状部分１４０ａを円盤状部分１４０ｂから切り離すことにした。なお、高い方の段差面１４０ｄと反対側の下面１４０ｆは後工程の熱間ローリングで必要となる段差でもある。 Therefore, by pressing the shaft-shaped portion 140a downward in the axial direction, the shaft-shaped portion 140a is formed into a disk shape along the cutting line 140c extending from the lower end portion of the downward inclination to the outer diameter surface of the shaft-shaped portion 140a. I decided to separate it from the part 140b. The lower surface 140f on the opposite side of the higher step surface 140d is also a step required for hot rolling in the subsequent process.

切り離した後の軸状部分１４０ａと円盤状部分１４０ｂが図２Ａ（ｆ）に示される。円盤状部分１４０ｂはリングギヤの最終の荒地（第２中間材１４１）である。この荒地１４１の外径は１５８ｍｍ、軸長（高さＨ）は４４ｍｍである。 The shaft-shaped portion 140a and the disc-shaped portion 140b after being separated are shown in FIG. 2A (f). The disk-shaped portion 140b is the final wasteland (second intermediate material 141) of the ring gear. The wasteland 141 has an outer diameter of 158 mm and a shaft length (height H) of 44 mm.

また軸状部分１４０ａはピニオンギヤの最終の荒地（第２中間材１４６）である。この荒地１４６の外径は６７ｍｍ、軸長（高さＨ）は１２１ｍｍである。 Further, the shaft-shaped portion 140a is the final wasteland (second intermediate material 146) of the pinion gear. The outer diameter of the wasteland 146 is 67 mm, and the shaft length (height H) is 121 mm.

最後に、荒地１４１と１４６をそれぞれ別工程で機械加工することで（ｇ）と（ｈ）の製品を得る。すなわち、荒地１４１をローリング（圧延）して外周面１４２ａとフランジ１４２ｂを有する形状にした後、第１のギヤ加工部としての外周面１４２ａをホブ切りすることで（ｇ）のリングギヤ１４２を得る。 Finally, the products (g) and (h) are obtained by machining the wasteland 141 and 146 in separate steps, respectively. That is, after rolling (rolling) the wasteland 141 into a shape having an outer peripheral surface 142a and a flange 142b, the outer peripheral surface 142a as the first gear processing portion is hobbed to obtain the ring gear 142 of (g).

また、荒地１４６の第２のギヤ加工部としての外周面をホブ切りすることで（ｈ）のピニオンギヤ１４７を得る。リングギヤ１４２の外径は、ローリング（圧延）の程度によりある程度増減可能なので、所要の外径を有するピニオンギヤ１４７を第２荒地１３０から無駄なく成形することができる。 Further, the pinion gear 147 of (h) is obtained by hobbing the outer peripheral surface of the wasteland 146 as the second gear processing portion. Since the outer diameter of the ring gear 142 can be increased or decreased to some extent depending on the degree of rolling, the pinion gear 147 having the required outer diameter can be formed from the second wasteland 130 without waste.

このように、本発明の製造方法によれば、従来の製造方法のように廃材（スクラップ２４６）を出さないで済むので、リングギヤ１４２やピニオンギヤ１４７の原価低減に有効である。また、リングギヤ１４２やピニオンギヤ１４７をセット鍛造することにより、材料費だけでなく製造コストも抑えることができる。 As described above, according to the manufacturing method of the present invention, it is not necessary to generate waste material (scrap 246) as in the conventional manufacturing method, which is effective in reducing the cost of the ring gear 142 and the pinion gear 147. Further, by forging the ring gear 142 and the pinion gear 147 as a set, not only the material cost but also the manufacturing cost can be suppressed.

（金型設備）
図２Ｂの（ａ）〜（ｆ）は、前述した熱間鍛造成形に使用する金型設備の概略を示している。この金型設備は、基本的に上型と下型で構成される（金型総数は２５種類）。上型と下型は、それぞれ１又は複数の型で構成される。複数の上型と複数の下型は、それぞれ同心状に配設される。 (Mold equipment)
(A) to (f) of FIGS. 2B show an outline of the mold equipment used for the above-mentioned hot forging molding. This mold equipment is basically composed of an upper mold and a lower mold (the total number of molds is 25 types). The upper mold and the lower mold are composed of one or more molds, respectively. The plurality of upper molds and the plurality of lower molds are arranged concentrically with each other.

上型を可動型、下型を固定型とした場合、上型を例えば２５００〜３５００ｔプレスで駆動する。また熱間の加熱温度は例えば９００〜１２６０℃である。 When the upper mold is a movable type and the lower mold is a fixed type, the upper mold is driven by, for example, a 2500 to 3500 t press. The heating temperature between heats is, for example, 900 to 1260 ° C.

図２Ｂの（ａ）は、素材１００を上下方向で圧縮する上型Ａ１と下型Ａ’２を示している。（ｂ）の横型Ａ’１は下型Ａ’２と一体であって、据込み鍛造時に鍛造品１１０の外径を規制するものである。（ｃ）は軸状部分１２０ａの押出し成形に使用する上型Ｂ１、下型Ｂ’２、横型Ｂ’１（下型Ｂ’２と一体）を示している。 FIG. 2B (a) shows an upper die A1 and a lower die A'2 that compress the material 100 in the vertical direction. The horizontal die A'1 of (b) is integrated with the lower die A'2, and regulates the outer diameter of the forged product 110 at the time of stationary forging. (C) shows the upper mold B1, the lower mold B'2, and the horizontal mold B'1 (integrated with the lower mold B'2) used for extrusion molding of the shaft-shaped portion 120a.

（ｄ）は円盤状部分１３０ｂを成形するための上型Ｃ１、Ｃ２、下型Ｃ’２、Ｃ’３、横型Ｃ’１（下型Ｃ’２と一体）を示すものである。横型Ｃ’１によって円盤状部分１３０ｂの外径が規制される。 (D) shows the upper mold C1, C2, the lower mold C'2, C'3, and the horizontal mold C'1 (integrated with the lower mold C'2) for forming the disk-shaped portion 130b. The outer diameter of the disk-shaped portion 130b is regulated by the horizontal type C'1.

（ｅ）は、前工程（ｄ）の軸状部分１３０ａと円盤状部分１３０ｂの周方向境界断面を薄肉化するための、上型Ｄ１、Ｄ２、Ｄ３、下型Ｄ’２、Ｄ’３、Ｄ’４、Ｄ’５、横型Ｄ’１（下型Ｄ’２と一体）を示すものである。横型Ｄ’１によって円盤状部分１４０ｂの外径が規制される。 In (e), upper molds D1, D2, D3, lower molds D'2, D'3, for thinning the circumferential boundary cross section of the axial portion 130a and the disc-shaped portion 130b in the previous step (d), It shows D'4, D'5, and horizontal type D'1 (integrated with lower type D'2). The outer diameter of the disk-shaped portion 140b is regulated by the horizontal type D'1.

上型Ｄ２と下型Ｄ’３の間において、軸状部分１４０ａと円盤状部分１４０ｂの周方向境界断面が圧縮されて薄肉化される。このように周方向境界断面が薄肉化されることで、（ｆ）の５工程において軸状部分１４０ａ（第２中間材１４６）を容易に切り離すことができる。また、この薄肉化により径方向外側への材料流れが生じ、円盤状部分１４０ｂの周縁部が軸線方向（上下方向）に肥厚化する作用が得られる。 Between the upper die D2 and the lower die D'3, the circumferential boundary cross section of the shaft-shaped portion 140a and the disk-shaped portion 140b is compressed and thinned. By thinning the peripheral boundary cross section in this way, the axial portion 140a (second intermediate member 146) can be easily separated in the five steps (f). Further, this thinning causes a material flow outward in the radial direction, and an action of thickening the peripheral edge portion of the disk-shaped portion 140b in the axial direction (vertical direction) can be obtained.

（ｆ）の５工程では、上型Ｅ１、Ｅ２、Ｅ３、下型Ｅ’１，Ｅ’２が使用される。上型Ｅ１と下型Ｅ’１，Ｅ’２によって円盤状部分１４０ｂの外周部が上下方向から挟まれて固定される。 In the five steps of (f), the upper molds E1, E2, E3 and the lower molds E'1 and E'2 are used. The outer peripheral portion of the disk-shaped portion 140b is sandwiched and fixed from the vertical direction by the upper mold E1 and the lower molds E'1 and E'2.

この状態で、上型Ｅ２、Ｅ３によって軸状部分１４６を下方にプレスして円盤状部分１４０ｂから切り離す。切り離し線１４０ｃが薄肉化されているので、切り離し時のプレス圧低減、打ち抜きパンチへの負荷軽減とパンチ寿命の延長を図ることができる。 In this state, the shaft-shaped portion 146 is pressed downward by the upper molds E2 and E3 to separate it from the disk-shaped portion 140b. Since the separation line 140c is thinned, it is possible to reduce the press pressure at the time of separation, reduce the load on the punch, and extend the punch life.

（円盤状部分と軸状部分の軸方向連続位置）
図３は、円盤状部分１４０ｂ（リングギヤ荒地）と軸状部分１４０ａ（ピニオンギヤ荒地）の軸方向連続位置の違いによる、両者の切り離し性への影響を示す図である。なお、図３の金型形状は図２Ｂを単純化して示している。 (Axial continuous position of disk-shaped part and shaft-shaped part)
FIG. 3 is a diagram showing the influence on the separability of the disc-shaped portion 140b (ring gear rough ground) and the shaft-shaped portion 140a (pinion gear rough ground) due to the difference in the continuous positions in the axial direction. The mold shape shown in FIG. 3 is a simplification of FIG. 2B.

図３で軸状部分１４０ａの外径が少し大きくなっている部分が、ピニオンギヤの第２のギヤ加工部の形成予定位置である。この形成予定位置に円盤状部分１４０ｂの内径側が連続している。図３左端列が軸方向連続位置が上側、中央列が軸方向連続位置が中央、右端列が軸方向連続位置が下側の場合である。なお、連続部分の軸方向長さは、図３左端列では薄肉化した寸法Ａであるが、他の寸法Ｂ、Ｃは薄肉化を省略している（Ａ＜Ｂ＝Ｃ）。 In FIG. 3, the portion where the outer diameter of the shaft-shaped portion 140a is slightly larger is the planned formation position of the second gear processed portion of the pinion gear. The inner diameter side of the disk-shaped portion 140b is continuous at this planned formation position. FIG. 3 is a case where the leftmost row has the axial continuous position on the upper side, the central row has the axial continuous position at the center, and the rightmost row has the axial continuous position on the lower side. The axial length of the continuous portion is the thinned dimension A in the leftmost column of FIG. 3, but the other dimensions B and C omit the thinning (A <B = C).

本願実施形態では、図３左端列のように、円盤状部分１４０ｂ（リングギヤ荒地）と軸状部分１４０ａ（ピニオンギヤ荒地）の軸方向連続位置を上側にしている。この上側位置は、切り離し工程で軸状部分１４０ａを押圧する方向とは反対側の軸方向端部である。 In the embodiment of the present application, as shown in the leftmost row of FIG. 3, the continuous positions in the axial direction of the disk-shaped portion 140b (ring gear rough ground) and the shaft-shaped portion 140a (pinion gear rough ground) are on the upper side. This upper position is an axial end portion on the side opposite to the direction in which the axial portion 140a is pressed in the cutting step.

この位置で両者を連続させることで、切り離し初期から切り離し中期にかけて、軸状部分１４０ａの外周面（第２のギヤ加工部の形成予定位置）に発生する歪が少なく、切り離し後の機械加工工程数を低減することができる。歪が少ないのは、前述した薄肉化による寸法Ａも有利に作用すると推測される。 By making both of them continuous at this position, there is less distortion generated on the outer peripheral surface of the shaft-shaped portion 140a (the position where the second gear processing portion is planned to be formed) from the initial stage of separation to the middle stage of separation, and the number of machining steps after separation is small. Can be reduced. It is presumed that the reason why the distortion is small is that the dimension A due to the thinning described above also has an advantageous effect.

これとは反対に、図３右端列のように軸方向連続位置を下側にした場合、切り離し初期で軸状部分１４０ａの外周面の下側段差部で切り離し抵抗により大きな傾斜ＮＧ１が発生する。また、切り離し中期では軸状部分１４０ａの外周面の上側段差部で切り離し抵抗により大きな膨らみＮＧ２が発生する。下側の傾斜ＮＧ１は、寸法Ｃを薄肉化（寸法Ａ）することである程度は低減するが、上側の膨らみＮＧ２は却って大きくなる。切り離し前の連続位置から切り離し完了までの距離が長いことにより、肉移動量が大きくなるからである。 On the contrary, when the continuous position in the axial direction is set to the lower side as shown in the right end row of FIG. 3, a large inclination NG1 is generated due to the disconnection resistance at the lower step portion of the outer peripheral surface of the axial portion 140a at the initial stage of disconnection. Further, in the middle stage of disconnection, a large bulge NG2 is generated due to the disconnection resistance at the upper step portion of the outer peripheral surface of the shaft-shaped portion 140a. The lower inclination NG1 is reduced to some extent by thinning the dimension C (dimension A), but the upper bulge NG2 is rather large. This is because the amount of meat movement increases because the distance from the continuous position before the separation to the completion of the separation is long.

また図３中央列のように軸方向連続位置を中央にした場合、切り離し初期では特に問題は見られない。しかし、切り離し中期で軸状部分１４０ａの外周面の上側段差部で切り離し抵抗により僅かな膨らみＮＧ３が発生する。切り離し前の連続位置から切り離し完了までの距離が本実施形態（左端列）より長くなるので、その分だけ肉移動量が大きくなるからである。 Further, when the continuous position in the axial direction is set to the center as shown in the center row of FIG. 3, no particular problem is observed at the initial stage of disconnection. However, in the middle stage of disconnection, a slight bulge NG3 is generated due to the disconnection resistance at the upper step portion of the outer peripheral surface of the shaft-shaped portion 140a. This is because the distance from the continuous position before the separation to the completion of the separation is longer than that of the present embodiment (leftmost row), so that the amount of meat movement is increased accordingly.

このように、円盤状部分１４０ｂ（リングギヤ荒地）と軸状部分１４０ａ（ピニオンギヤ荒地）の軸方向連続位置を上側にしない場合、傾斜や膨らみの変形部分（ＮＧ１〜３）を切り離し後の機械加工で修正する必要があり、その分だけ工程数が増加してコストアップになってしまう。 In this way, when the axial continuous position of the disk-shaped portion 140b (ring gear rough ground) and the shaft-shaped portion 140a (pinion gear rough ground) is not set upward, the deformed portion (NG1 to 3) of inclination or bulge is separated and then machined. It is necessary to correct it, and the number of processes increases by that amount, resulting in an increase in cost.

以上、本発明の実施形態について説明したが、本発明は前記実施形態に限定されることなく種々の変形が可能である。例えば前記実施形態では０工程（材料）から１〜３工程を経て第２荒地１３０を成形したが、素材の種類や第２荒地１３０の形状によっては、０工程（材料）から第２荒地１３０を直接成形することも可能である。その場合は図２Ｂの（ｂ）と（ｃ）の工程を省略することができる。
可能である。 Although the embodiments of the present invention have been described above, the present invention is not limited to the above embodiments and can be modified in various ways. For example, in the above embodiment, the second wasteland 130 is formed through steps 0 (material) to 1 to 3, but depending on the type of material and the shape of the second wasteland 130, the second wasteland 130 may be formed from step 0 (material). It is also possible to mold directly. In that case, the steps (b) and (c) of FIG. 2B can be omitted.
It is possible.

１００：素材 １１０：鍛造品
１２０：第１荒地 １３０：第２荒地
120a、130a、140a：軸状部分 １３０ｂ、１４０ｂ：円盤状部分
１４０：第１中間材 １４０ｃ：切り離し線
１４０ｄ、１４０ｅ：段差面 １４０ｆ：下面
１４１、１４６：第２中間材（荒地） １４２：リングギヤ
１４２ａ：外周面 １４２ｂ：フランジ
１４７：ピニオンギヤ ２４０：第１中間材
２４０ａ：リング状部分 ２４０ｂ：円盤状部分
２４０ｃ：破線部 ２４１：第２中間材
２４２：ギヤ粗材 ２４６：スクラップ 100: Material 110: Forged product 120: First wasteland 130: Second wasteland
120a, 130a, 140a: Shaft-shaped part 130b, 140b: Disc-shaped part 140: First intermediate material 140c: Dotted line 140d, 140e: Stepped surface 140f: Lower surface 141, 146: Second intermediate material (rough ground) 142: Ring gear 142a : Outer peripheral surface 142b: Flange 147: Pinion gear 240: First intermediate material 240a: Ring-shaped part 240b: Disc-shaped part 240c: Dashed line part 241: Second intermediate material 242: Gear rough material 246: Scrap

Claims (4)

円柱状の素材を熱間据込鍛造することにより、リングギヤの荒地としての円盤状部分と、当該円盤状部分の中心部から軸線方向片側方向に延びたピニオンギヤの荒地としての軸状部分とを有する中間材を成形する第１工程と、
前記円盤状部分と前記軸状部分の周方向境界断面を上下型でプレスして薄肉化する第２工程と、
前記軸状部分を軸線方向片側方向に押圧することにより、当該軸状部分を前記円盤状部分から薄肉化した前記周方向境界断面で切り離す第３工程と、
前記第３工程で前記円盤状部分から前記軸状部分を切り離して得られたリング状部材を、ローリングによって径寸法を拡大すると共に、当該リング状部材の外周面に後工程でギヤを加工するための第１のギヤ加工部を形成する第４工程と、
前記第３工程で切り離した前記軸状部分の外周面に、後工程でギヤを加工するための第２のギヤ加工部を形成する第５工程と、
を有し、
前記第１工程と前記第２工程において、前記円盤状部分と前記軸状部分が連続する連続位置を、前記第２のギヤ加工部の形成予定位置であって、前記第３工程で前記軸状部分を押圧する方向と反対側の軸方向端部に設けることを特徴とするリングギヤとピニオンギヤの製造方法。 By hot-installing and forging a columnar material, it has a disk-shaped portion as a rough ground for the ring gear and a shaft-shaped portion as a rough ground for the pinion gear extending in one axial direction from the center of the disk-shaped portion. The first step of molding the intermediate material and
The second step of pressing the circumferential boundary cross section of the disk-shaped portion and the shaft-shaped portion with an upper and lower mold to make the wall thinner.
A third step of pressing the shaft-shaped portion in one side in the axial direction to separate the shaft-shaped portion from the disk-shaped portion at the circumferential boundary cross section.
In order to expand the diameter dimension of the ring-shaped member obtained by separating the shaft-shaped portion from the disk-shaped portion in the third step by rolling and to process a gear on the outer peripheral surface of the ring-shaped member in a subsequent step. The fourth step of forming the first gear processing portion of
A fifth step of forming a second gear processing portion for processing a gear in a subsequent process on the outer peripheral surface of the shaft-shaped portion separated in the third step.
Have,
In the first step and the second step, the continuous position where the disk-shaped portion and the shaft-shaped portion are continuous is the position where the second gear processing portion is planned to be formed, and the shaft-shaped portion is formed in the third step. A method for manufacturing a ring gear and a pinion gear, which is provided at an axial end portion opposite to the direction in which the portion is pressed. 前記第１工程において、前記素材を軸線方向片側方向に前方押出しすることにより前記軸状部分を成形した後、前記円盤状部分を成形することを特徴とする請求項１の製造方法。 The manufacturing method according to claim 1, wherein in the first step, the shaft-shaped portion is molded by extruding the material forward in one side direction in the axial direction, and then the disk-shaped portion is molded. 前記第１工程において、前記円柱状の素材を第１の上下型でプレスすることにより軸長と外径の比が８５％〜９５％の鍛造品を成形し、当該鍛造品を第２の上下型でプレスして当該鍛造品を軸線方向片側方向に前方押出しすることにより前記軸状部分を成形した後、前記軸状部分の基端側を第３の上下型でプレスして拡径することにより前記円盤状部分を成形することを特徴とする請求項１の製造方法。 In the first step, the columnar material is pressed with the first upper and lower molds to form a forged product having a shaft length to outer diameter ratio of 85% to 95%, and the forged product is pressed into the second upper and lower parts. After forming the shaft-shaped portion by pressing with a mold and extruding the forged product forward in one side in the axial direction, the base end side of the shaft-shaped portion is pressed with a third vertical mold to expand the diameter. The manufacturing method according to claim 1, wherein the disk-shaped portion is formed by the above method. 前記第２工程において、前記薄肉化による径方向外側への材料流れにより前記円盤状部分の周縁部を肥厚化することを特徴とする請求項１から３のいずれか１項の製造方法。 The production method according to any one of claims 1 to 3, wherein in the second step, the peripheral edge portion of the disk-shaped portion is thickened by the material flow outward in the radial direction due to the thinning.
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