JPS58181450A - Manufacture of thick-walled gear or the like - Google Patents

Abstract

PURPOSE:To manufacture very easily gear parts, etc. whose all uneven faces consist of a smooth cut face, by continuously executing heat punching and heat shaving by one stroke, in a state that a thick-walled blank material is heated to a necessary temperature. CONSTITUTION:In general, a thick-walled blank material 1 consisting of carbon steel of S45C, etc. is charged into a heating furnace 2, and is heated to a temperature (600-900 deg.C) at which no constituting cutter edgelike adhering matter is generated on a die at the time of working. Subsequently, the heating blank material 1 is charged into a press die A provided with a special two-stage die, and base contour blank forming approximate to a product contour, and shaving are executed continuously by one stroke of a punch 3. That is to say, the heating blank material 1 is charged into the press die on which the punch 3, a preliminary contour punching die 5 opposed to said punch, and a shaving die 6 are provided in tages. In this way, a base contour blank 17 is hot-formed by one stroke by this press die, and also the blank 17 is finished to a product shape by hot shaving, and is cooled, by which thick gear, etc. 19 are obtained.

Description

[Detailed description of the invention] The present invention relates to a method for manufacturing ti and y meat gears.

When manufacturing parts that have M irregularities in closed contours, such as gears, the conventional method is to cut the blank with a hob cutter or pinion cutter, and then finish with a gear grinder as necessary. However, it has the disadvantage of low efficiency and high processing costs. An alternative method is a precision punching method or a method in which a blank is pressed and sheared to produce a sheared element body, and this element body is finished by shaving punching or the like. However, the precision punching method requires a special and expensive press, so it lacks versatility.
It is difficult to finish a thick plate tube without causing a fractured surface such as O- or above, and it is especially difficult to process gears with large modules into a smooth cut surface with high precision. On the other hand, the shaving punching method has the advantage that it does not require a special press, but if the plate is thick or the contour is complex, it will require multiple machining processes, two or more times.
Moreover, there is a drawback in that even if the machining allowance is reduced, a fractured surface remains. For this reason, a high-speed shaving method has been considered, but this method also requires a special press and is noisy, creating problems in the working environment. Since the load was heavy and the cutting edge was abrasive, KVi did not have a good finished surface and was glossy.

The present invention was devised after repeated research in order to eliminate the disadvantages of the conventional method. To provide an elegant method for manufacturing thick-walled gears which can extremely easily manufacture gear parts having smooth cut surfaces and which requires less wear on blades and less load.

In order to achieve this object, the present invention heats a thick-walled material to a required temperature and successively performs heating punching and heating shaving in one process using the same press die to obtain the desired closed contour product 1 with unevenness. In order to achieve this, the thick-walled material is heated to a temperature that does not produce built-up edge formations, and the heated thick-walled material is passed through a punch and an opposing pre-contour die and a shaving die. The method is characterized in that a press die KM is placed on the press die, and within one stroke of the press die, an elementary contour blank is hot-formed, and the edge of the elementary contour blank is hot shaved to give a product shape, and then cooled. It is something.

Embodiments of the present invention will be described below based on the accompanying drawings.

FIG. 1 schematically shows a method for manufacturing thick internal gears according to the present invention, where l is a thick wall material and a plate corresponding to the thickness of the gears to be manufactured, such as gears, sprockets, cams, etc. It has a thickness of tf and has an arbitrary shape passed through a board, such as a circle.

Piece, S) It is shaped like an IJ tube. The material is generally carbon steel, but materials that are difficult to machine, such as S 4 s C18CC13C, 8841, are particularly advantageous to the present invention.

When manufacturing gears, the thick-walled material 1 is first charged into a heating furnace 2 and heated to a required temperature. The heating temperature needs to be higher than the temperature at which build-up edge-like deposits do not occur on the die during processing, which will be described later.In the case of carbon steel, the shaving temperature is generally 600 to 900°C.
This is the range. At temperatures below 600° C., fractured surfaces occur during blank contour blank forming and shaving, regardless of the machining allowance. A temperature of 900°C or higher is desirable from the standpoint of reducing the required load, but it may cause oxidation of the product,
Keyu is undesirable from the point of view of the size of Dareyawanboku and the medium size #kinuta with Mayuyaki.

Heating Furnace 2Fi Atmosphere Four Air Furnace, Resistance Heating Furnace, High Frequency I1
j The model such as 47JJ heat furnace is optional, but pot type,
In the case of the continuous type, it is necessary to adjust the temperature distribution of the metal rod of the thick cable material to be uniform. High frequency induction heating is advantageous in terms of scale reduction ft1a, and is suitable for hardening uneven parts (such as 1m ahead) of a product in a housing.
By using high-frequency induction heating, only the necessary parts of the inner material l can be locally heated at high temperature in a ring shape, and if this method is adopted,
After performing basic contour forming and shaving, which will be described later, it can be easily hardened by placing it in cooling oil.

Next, 1't% of the heated thick-walled material obtained in the previous process is charged into a press type AK equipped with a special two-stage die, and in one stroke of a punch, a raw contour blank that approximates the product contour is continuously shaved. The processing speed is 0, which is the normal press speed.
, 1 to 0.4 m/s is sufficient.

Figure 2 shows an example of the press mold used in this process, and the third
The figure schematically shows the entire process. In this embodiment, the punch is placed on the lower side and the die is placed on the upper side, but it goes without saying that the opposite arrangement may be used. A punch 3 has an uneven surface 31 that matches the contour of the product, and is fixed to the bolster 15 at its lower part. Reference numeral 4 denotes a temporary presser supported by a die cushion bin, and a protrusion 14 for reducing sag is formed on the upper surface in the inner zone of the sandwich width W. The die is a pre-contour punching die to which the heated thick-walled material 1 is applied on the surface facing the 5ti punch 8, and a forming hole 51 with unevenness similar to the product contour is formed in the inner diameter part. Clearance C1xfi between this forming hole 51 and the uneven surface 31 of the punch 3 Required machining allowance δ1
The shaving clearance CtB is added to the shaving clearance CtB.

A shaving chair 6 is provided behind the preliminary contour punching die 5, and has a shaving hole 61 with an uneven shape that matches the contour of the product. It is desirable that the clearance CtjI of the hole 51 is set so that the machining allowance in this step is approximately 8 inches or less of the plate thickness.

Reference numeral 7 denotes a space formed between the preliminary contour punching die 5 and the shaving die 60, which is a space sufficient to discharge the ring-shaped waste formed in the previous stage when shaving the nine element contour black. It is necessary to have one. The space 7 may be formed by combining the pre-contour punching die 5 and the shaving die 6 with a columnar spacer, but preferably the method shown in FIG. 2 is used.

In other words, in this second figure, the breath ram (slide)
At the same time, a preliminary contour punching die 5 is fixed to the tip of the piston 10, which is formed in the breath ram 8, passed through the hollow space 9, and then the piston 101 comes out in the center. By installing a pressing member (surge ring or hydraulic pressure) 11 inside, the pre-contour punching die 5 and the shaving die 6 can be freely connected to each other, and furthermore, the shaving waste on the outside of the forming hole of the pre-contour punching die 5 is accommodated. A ring-shaped recess 12 is formed for this purpose. It is necessary that the depth of the 12 ring-shaped recesses is as small as the thickness of the heated thick-walled material 1'. If such a method as shown in Fig. 2 is adopted, not only will it be easier to remove shaving debris, but the forming hole 51 of the pre-contour punching die 5 will have the function of guiding the blank during the shaving process. Therefore, a uniform shaving deposit can be formed. +3Fi knockout bar.

In this process, a nine-thickness piece of wood 1', which has been heated to a predetermined temperature in the previous step, is mounted and positioned between the punch 3 and the pre-contour punching die 5, as shown in FIG. 3(a). Next, the pre-contour punching die 5 and the punch 3 are moved relative to each other, and a forward force is applied to the punch 3. In this embodiment, when the breath ram 8 is operated and the shaving die 6 is lowered, the piston 10 is retracted and the shaving die 6 and the preliminary contour punching die 5 are combined.

Then, in this state, as shown in the third circumferential movement), the heated inner material 1'
is sandwiched between the punch 3 and the punch shoulder and the forming hole 51 start punching, and when the forming hole 51 reaches the punch shoulder, the thick material passes through the pre-contour punching die. 1' to the elementary contour map 97 that approximates the product contour.
77 is hot formed. FIG. 4(a)) shows the thick material 1' and the blank contour blank 17 at this stage.

In addition, when the protrusion 14 is formed on the temporary presser foot 4,
Since the protrusions 14 bite into the heated thick-walled material 1' and suppress the material from escaping, the sag of the blank contour blank 11 is reduced.

Next, if the relative movement between the punch 3 and the two-stage die is continued, the heated raw contour blank 17 will be forcibly moved toward the shaving die 6 by the pressing force of the punch 8, and the raw contour blank 17 will be moved toward the shaving die 6. The upper outer edge 17' is applied to the lower edge 62 of the shaving die 6.

At this time, in this embodiment, the shaving die 6 is combined with the pre-contour punching die 5, and the forming hole 51 cuts the blank contour blank 17 until the blank contour blank 17 reaches the subsequent shaving die 6. Provide appropriate guidance. Then, due to the continuous forward movement of the punch 8, the third
As shown in Figure (C), the edge of the basic contour blank 17 is cut with the edge of the shaving die 6, and the hot punched surface in the previous process is smoothed. At this time, +8 fl of ring-shaped waste from the basic contour blank 17 is captured in the space 7 between the lower surface of the shaving die 6 and the upper surface of the preliminary contour punching die 5.

In this way, the shaving die 6 cuts the raw contour blank 17.
Shaving is completed by reaching the position where the product 19 penetrates the shaving die 6 and the product 19 remains in the shaving hole 61 of the shaving die 6 and is integrated with the product 19 as shown in FIG. 3(d). A ring wiper 18 is accommodated in the space 7 between them. FIG. 4(C) shows an example of the ring wiping 18 and product 19 at this stage.

Now, the forming stroke is IP: J'L, and the punch 3 and the two-stage die are separated, so that the hole 1a is made as shown in Fig. 3 <e). It is lifted up and discharged by air, etc. Also,
As soon as the shaving die 6 is pulled up, the pressure member 11 in the cavity 9 pushes out the piston 10, so that the preliminary contour punching die 5 and the shaving die 6 are separated by a large distance. Therefore, the ring wiper 18 can be easily removed outward by applying air or the like. And product 19
Take it out of the mold for a knockout par 13.

If quenching is desired, the product is immediately poured into cooling oil or cooled at a cooling rate higher than that of air cooling, or if quenching is not desired, it is cooled appropriately to become the desired product.

As described above, the present invention is characterized by heating a thick inner material, and forming and shaving the heated thick inner material into an elementary contour blank in the same mold shearing process. Gears with such severe contours can be manufactured by using gold tooth surfaces with smooth cut surfaces.

The present inventors heated a circular blank, set the nominal takeoff type J at the outer periphery of the tooth tip from -2 to +2-, and directly shaved a gear (tooth tip circle diameter l 48 m, module 3 (2
) Inho I) Knee ) Gear) We also conducted an experiment to manufacture 1. As a result, even if the heating temperature was appropriate, a fractured surface occurred at the tooth tip regardless of the amount of machining allowance.

This is because during shaving, the evacuation of chips between adjacent teeth is inhibited, and as a result, the chips are pushed radially outward, causing the tooth tips to be sheared apart under tensile stress.

Therefore, with this method, a product with good S degree and a good cut surface cannot be obtained.

Therefore, in order to facilitate the discharge of chips, the present inventors
A tooth profile blank with a uniform machining allowance over the entire circumference was prepared in advance, and a gear was manufactured by heating and shaving it. As a result, a range where the actual machining allowance is small (for example, blank thickness low, heating source Pi 800°C, 84
5Ct, δ at IC = 0.23~0.73m
) Te had a flat surface at the tooth tip, but when the machining allowance was made thicker, chips from adjacent m-planes interfered with each other, resulting in a fractured surface. This is because as the machining allowance increases, the ratio of the shaving mechanism decreases, and a cut surface is formed by the punching mechanism, resulting in a fractured surface at the tip of the tooth, which is in a state of tensile stress. Further, using a tooth-shaped blank as in this method is not appropriate considering that blanks are generally produced by cold punching. In particular, when punching a difficult-to-process thick plate into a difficult-to-process material, cracks appear in the teeth, making it difficult to put it to practical use.

However, according to the present invention, a method is adopted in which a thick material such as a strip is subjected to heating punching and heating shaving in the same process to form a blank having a uniform machining allowance all around the outer circumference of the contour in the first stage. Therefore, it is easy to manufacture blanks, and even if the mouth surface of the Iill type blank blank has a fractured surface, the depth of the fractured surface is as shallow as about 0.1 mm under the above conditions. It doesn't matter how much.

Moreover, since the raw contour blank produced by heating punching is subsequently shaved in the same process with a machining allowance larger than the depth of the fractured surface, it is easy to remove chips, and chips from adjacent surfaces do not interfere with each other. , a smooth cut surface is formed.

Although the present invention is suitable for manufacturing thick-walled vehicles made of carbon steel, it is also highly effective when applied to a method for manufacturing thick-walled stainless steel vehicles.

In other words, this material has a high punching load and high springiness, so during cold working, there are problems in that the die tends to rattle or loosen due to the release of elastic energy when the material is cut, and the load itself is large. However, if you illegally heat the material to at least 300 degrees Celsius, maintain that temperature, and then pass it through a two-stage die in the same process, you can perform cold processing. Average flat 1'
The mold can be formed with less load and without the mold being cut.

In addition, the method of the present invention involves blanking and sea-shaving thick-walled materials under heated conditions, and therefore, the dimensional accuracy can be improved by making the mold larger in advance in anticipation of thermal expansion. I can do it. Mold production can be easily handled by using the wire cut borrowing function, for example.

Furthermore, it goes without saying that the present invention can be applied not only to external teeth but also to internal tooth formation, or to simultaneous formation of external and internal teeth.

Next, specific examples of the present invention will be shown.

Example 1 By applying the present invention, the tooth tip circle diameter pI48■, the involute lIl single module 3 was made of 845C material (c:o,
445 Akebono;, Si:0.24 Di;, Mn
20, 74%, P: o, ozl, S: 0.01%,
Cu: 0.01%, N1=0.01%, er:o,
o31, Ni + Cr: 0.04%), plate thickness 10■
Manufactured from.

(1) First, Atsunai lumber with finished upper and lower surfaces was placed in an electric furnace and heated at 800° C. for 15 minutes to achieve uniform temperature distribution throughout. 100 as a press.
) Using a crank press (the one shown in Figure 2 of the mold structure),
Actual shaving removal δ, ′I! cO, 5 mm, and 0.5 in the clearance tube C4B during tooth profile blank molding.
3mm+ closed. In addition, shaving clearance c4.
-4-o, o s ■. Average processing speed Wt Fio,
The speed was set at 1 m/sec.

In carrying out I, the heated Atsunai material was taken out of the furnace, the process of single outline punching and shaving was completed within 10 seconds, and the product was placed in cooling oil to cool. As a result, gears with smooth cut surfaces with no fracture surfaces on all tooth surfaces were superior, regardless of the width of the tooth.

■The relationship between the convergence and the outer diameter of the obtained product is @5
The method and shape of the mafc product teeth are shown in FIG. 6 in comparison with a shaving mold.

The product dimensions are 0.39 mm and 0.30 m smaller than the die method at the tip and the tooth bottom, respectively, but this is approximately equivalent to the shrinkage after cooling, and is smaller than the actual production. It can be seen that by taking thermal expansion into account, product quality can be improved.

■Next, measure the straightness of the tooth tip and tooth bottom by width W =
The results for 0.5, 1.5, and 14.5 are shown in Figure 7. Figure wJ8 shows I! when gears are machined directly from a heated round blank by shaving. It can be seen that when the straightness of part a1 is determined and the heating tooth profile blank punching and heating shaving tube are performed within one stroke as in the present invention, the accuracy is significantly improved.

(2) In the present invention, when the effects of varying the punching-shaving temperature are examined, the results are as shown in FIGS. 9 and 10. Fig. 9 shows the effect on the bending, and Fig. 10 shows the effect on the curve, and it can be seen that 700 to 900°C is the optimum range. Note that this is the case when no protrusions are attached to the temporary presser, and can be significantly reduced by attaching protrusions to strengthen the restraint during the punching process. In addition, if the one-stroke heating punching-shaving diagram is shown at a heating temperature of 800°C, the 11th
As shown in the figure. From this FIG.
It can be seen that even if a broken surface occurs during the punching process, the finished product is finished by shaving in the second process, including the broken surface. In addition, in this example, it was confirmed that the cut surface was clean in all cases of 9th generation.

■Also, the heating temperature is 800℃, the width is 1■, and the thickness is 0.5.
The above-mentioned cars were manufactured from 8841 and 20 sheets of SCM415 material under the following conditions, and in this case as well, a product with a smooth cut surface on all lII surfaces was obtained.

In the case of the above-mentioned failures and defects, when producing closed contour products with irregularities such as granite and sprockets, the Atsunai material is heated to a temperature that does not generate build-up edge-like deposits, and the punch and blank contour punching die are It is attached to a press made of stepped shaving dies, and hot punching is performed in the -stroke.
In addition to creating a raw contour blank with a uniform machining allowance tube over the outer circumference of the contour, this raw contour blank tube is heated and sold to produce a product, so it is possible to produce thick plates that are difficult to process without using special press equipment. From this, it is possible to easily manufacture a table with good dimensional accuracy and a smooth cut surface on the entire thin surface.Moreover, the required load can be reduced due to hot working, and the deposits on the built-up edge can be welded and separated from the die cutting edge. Since there is no need to do this, excellent effects such as less deterioration of the mold can be obtained.

[Brief explanation of the drawing]

Fig. 1 is an explanatory diagram schematically showing the method for manufacturing both vehicles according to the present invention, Fig. 92 is a longitudinal side view showing an example of a press die used in the present invention, and Figs. 4(a) to 4(d) are perspective views showing an example of the creation at the processing stage of FIG. 3, and FIG. A graph showing the relationship between the product and the width, Fig. 6 is a plan view comparing the die shape and the shape of a part of the product, Fig. 7 is an explanatory diagram showing the straightness of the teeth of the product of the present invention, and Fig. 8 is a graph showing the relationship between the product and the width of the part. An explanatory diagram showing detailed straightness when shaving gears directly from a round blank, Fig. 9 is a graph showing the relationship between shaving temperature and curvature in the present invention, and Fig. 10 is a graph showing the relationship between shaving temperature and curvature. , and FIG. 11 are load-stroke diagrams for various machining allowances. l...Thick wall material, 1'...Heated thick wall material, 3...
Punch, 5... Preliminary contour punching die, 6... Shaving die, 7... Space, 17... Basic contour blank, 19... Product. ! Tadashi Murakawa Daido
Yasutoshi Okawa
Takeo Nakagawa Figure 3 (a) (b) Busy) ↓ Figure 4 (a) (b) (c) (d) Figure 6 Figure 9 Figure 10 )
＞Ehi J7'i1 Each Δ((OC)7 Fig.
Figure 8 Procedural Amendment (Method) August 7/11, 1981 1, '1 O ('1 indication Showa 5741- Patent Station 1 No. 68500 No. 3
, each Tokyo Metropolitan Government that serves Th1i City, Togo/T[I/da number S Tsuchiya Building ゛Ichizume S Otsugu 3911g July 2711, 1981 Amendment Contents 1 Specification of the present application, page 18, No. 11 The line ``As shown in Figure 6'' should be corrected as follows. "As shown in Figure 6, the solid 4I in Figure 6 is the Gui contour,
Point IIi! is the product shape. 2. Figure 6 of the drawings attached to this application is corrected as shown in the attached sheet.

Claims (1)

[Claims] 1. A thick-walled material is heated to at least a required temperature that does not cause deposits such as built-up edges, and the heated thick-walled material is passed through a punch and a pre-contour punching die and a shaving die in opposition to the punch. The raw contour blank is hot-formed in the press mold, and the edge of the raw contour blank is hot shaved to give a product shape, and then cooled. A manufacturing method for thick-walled gears. 2. The heating temperature for thick-walled materials is 600 to 90 in the case of carbon steel.
A method for manufacturing thick internal gears according to claim WJ1, wherein the temperature is in the range of 0°C. 3. The press mold has a space between the pre-contour punching die and the shaving die, and the heated thick material passes through the pre-contour punching die by the forward force of the punch, forming a plain contour blank, which is then passed through the subsequent shaving die. The forming hole of the preliminary contour punching die guides the raw contour blank until the blank is processed by the shaving die, and the space traps ring-shaped debris generated when the blank is processed with the shaving die A method for manufacturing thick internal gears according to claim 1. 4. A thick internal gear according to claim 1, in which a protrusion is formed on the plate holder, and the protrusion is injected into the heated thick-walled material to perform basic contour blank forming and shaving in one stroke. Manufacturing method.