U.S. patent number 3,580,027 [Application Number 04/780,390] was granted by the patent office on 1971-05-25 for gear rolling.
This patent grant is currently assigned to Lear Siegler, Inc.. Invention is credited to David W. Daniel, Warren C. McNabb.
United States Patent |
3,580,027 |
Daniel , et al. |
May 25, 1971 |
GEAR ROLLING
Abstract
Method and apparatus for producing gears from circular blanks by
rolling them in metal deforming pressure contact with one or more
toothed dies. The configuration of the space between the teeth of
the die or dies is carefully controlled so as to provide surfaces
which prevent the formation of "rabbit ears" and which accordingly
eliminates the "cold shut" previously located at the crests of the
teeth of gears rolled from circular blanks.
Inventors: |
Daniel; David W. (Birmingham,
MI), McNabb; Warren C. (Detroit, MI) |
Assignee: |
Lear Siegler, Inc. (Santa
Monica, CA)
|
Family
ID: |
25119465 |
Appl.
No.: |
04/780,390 |
Filed: |
December 2, 1968 |
Current U.S.
Class: |
72/98; 72/108;
29/893.32 |
Current CPC
Class: |
B21H
5/02 (20130101); Y10T 29/49471 (20150115) |
Current International
Class: |
B21H
5/00 (20060101); B21H 5/02 (20060101); B21h
005/02 () |
Field of
Search: |
;72/95,98,102,107,108,110,365,366,469 ;29/159.2 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Larson; Lowell A.
Claims
We claim:
1. A gear rolling die in the form of a circular gear having a
rolling diameter and having teeth which are tapered longitudinally
to have crests of increasing height and tooth spaces of increasing
depth, and in which the surfaces at the bottoms of the tooth spaces
at and adjacent the roots of the die teeth are disposed to prevent
formation of "rabbit ears" on a work gear blank as the die
displaces metal therefrom by intercepting "rabbit ears" as they
tend to form directly adjacent the tooth spaces being formed in a
work gear and guiding the flow of metal toward the middle portions
of the gear teeth as they are formed.
2. A die as defined in claim 1, the die teeth being of increasing
crest diameter and of diminishing root diameter from end to end,
the cross-sectional area of the tooth portions within the rolling
diameter in any radial plane being generally equal to the area of
the tooth space portions outside such rolling diameter, and the
surfaces of the roots and tooth flanks of the portions of the tooth
spaces being shaped to guide metal displaced from a gear blank by
penetration thereinto of teeth of the die toward the middle portion
of the gear teeth.
3. A die as defined in claim 2, the die teeth being of increasing
crest diameter and of diminishing root diameter from end to end,
the cross-sectional area of the tooth portions within the rolling
diameter in any radial plane being generally equal to the area of
the tooth space portions outside such rolling diameter, and the
root surfaces of the tooth spaces of the die being of increasing
depth from the flanks of the die teeth toward the middle portion
thereof.
4. A die as defined in claim 3 in which the die teeth increase in
crest diameter and decrease in root diameter generally equally from
one end to the other.
5. A die as defined in claim 4 in which the rate of increase in
crest diameter from one end to the other of the die teeth is
substantially uniform.
6. The method of forming gears which comprises rolling a gear blank
in contact with a gearlike die, causing progressive penetration of
the teeth of the die into the periphery of the blank to form tooth
spaces in the blank and to displace material radially outwardly
into teeth intermediate the tooth spaces, and confining and guiding
the material of the blank as it is displaced radially outwardly to
prevent local displacement of material directly adjacent the sides
of the tooth spaces as they are formed.
7. The method of claim 6 which comprises providing a pair of
diametrically opposed dies having tapered teeth, and feeding the
blank axially through the space between the dies.
8. The method of claim 7 in which the die teeth increase in crest
diameter and decrease in root diameter generally equally from one
end to the other.
9. The method of claim 8 in which the axes of the dies and the axis
of the blank are parallel.
10. A die as defined in claim 1 in which in diametral planes
adjacent the zone at which the die teeth merge into the rolling
diameter, the bottom surfaces of the tooth spaces incline from
approximately the rolling diameter toward the center of the tooth
spaces and form a generally V-shaped surface effective to displace
metal displaced by tooth portions of the die from the blank toward
the central portions of the spaces between the die teeth.
11. A die as defined in claim 1 in which the die teeth have
substantially constant leads as measured at constant radial
distance from the die axis.
12. A die as defined in claim 1 in which the die teeth have a
substantially constant chordal thickness as measured at the rolling
diameter.
13. A die as defined in claim 12 in which the chordal width of the
space between the die teeth as measured at the rolling diameter is
substantially constant and substantially equal to the chordal
thickness of die teeth as measured at the rolling diameter.
14. A die as defined in claim 1 in which the width of the die teeth
at the starting end thereof is substantially equal to the tooth
spacing.
Description
BRIEF SUMMARY OF THE INVENTION
Several different methods of rolling gears from circular blanks
have been employed, but in general these have resulted in causing
the metal displaced from a circular blank to be formed upwardly
into separate projections which are referred to as "rabbit ears."
These projections eventually reach the bottom of the space between
the teeth of the rolling die or dies and are forced together,
leaving opposed abutting surfaces extending into the tooth from the
crest thereof, which are commonly referred to as "cold shuts."
The methods of rolling gears which have produced this phenomenon
include the rolling of gears between a pair of opposed gearlike
dies in which the dies are relatively moved toward each other into
the material of the circular blank. It also includes rolling
operations in which the circular blank is acted on by opposed
oppositely moving tools in the form of modified racks. It also
includes operations in which two or more rolling dies are generally
tapered either with their axes parallel or crossed, and in which
the circular blank is advanced axially through the space between
the rolling dies.
In accordance with the present invention it is preferred to employ
a pair of opposed specially modified rolling gearlike dies. With
this arrangement it is of course apparent that each of the dies
opposes the lateral thrust of the other so that it is unnecessary
to provide extremely rigid support for the work blank as it is
rotated during the tooth generating operation. However, in its
broadest aspect the present invention may be practiced with a
single die providing the die and gear blank are adequately
supported against lateral displacement.
In the operation the gear blank is moved axially relative to one or
both of the rolling dies. Where the dies are provided in an opposed
pair, the axial movement of the blank is through the space between
the dies, and more specifically, the feeding movement of the gear
takes place with its axis occupying a plane parallel to the axes of
both dies.
In order to continuously prevent the local displacement of metal at
the sides of the tooth spaces as they are being formed in the gear,
which results in the so-called "rabbit ears," the spaces between
the teeth of the die or dies is given a configuration so that
surfaces thereof prevent the formation of the "rabbit ears" and
cause the metal displaced from the tooth spaces of the blank to
produce a flow of metal toward the center of the teeth.
In general, this may of course be accomplished by providing dies
which have teeth and tooth spaces appropriately tapered to
accomplish the foregoing result. However, since the shape of the
tooth as it is being generated by a flow of metal displaced from
the tooth spaces of the blank is not critical during intermediate
stages, it is sufficient to provide root surfaces on the die
sufficient to cause the metal displaced by the die teeth to flow
laterally into the median portion of the teeth of the blank. Only
in the portion of the die or dies which produce the final shape of
the teeth is it critically important to have the tooth spaces
including the flanks adjacent the root and usually also the root
surfaces, to be configured to produce the required tooth
configuration of the work gear.
The foregoing results are accomplished in general by providing a
die which at one end has a smooth circular cross section whose
diameter is the generating diameter of the die or substantially
equal thereto. From this circular end of the die teeth extend to
the other side of the die which increase in height to give a
generally conical outside diameter. Also, the spaces between the
teeth increase generally uniformly in depth. At the ends of these
teeth and tooth spaces where they run out into the cylindrical die
form, the tooth and tooth spaces may be of equal circumferential
extent. Moreover, measured along the same diameter throughout the
length of the teeth from end to end, the teeth and tooth spaces may
remain of equal circumferential extent. Alternatively, this
condition need not prevail, so long as in any radial plane, the
dies provide adequate space to receive the displaced metal from
tooth spaces of the gear blank, and have surfaces which shape the
flow of displaced metal to prevent formation of "rabbit ears."
It is important to provide a carefully matched die or pair of dies
to a cylindrical work piece blank to produce the required results.
It is of course obvious that all of the metal displaced from the
tooth space of the blank goes into the portion of the teeth
extending radially outwardly beyond the original diameter of the
blank. This statement of course is subject to recognition of the
fact that in rolling a gear of finite axial dimension, some
material may be displaced axially at one side or the other or both,
of the blank. However, the intermediate portion of the blank, or
intermediate blanks where a number are rolled in a continuous
sequence, do not exhibit this axial flow and hence, the die should
be designed to accommodate all of the metal displaced from the
tooth spaces and to form it into the required upper portion of the
teeth.
It is accordingly an object of the present invention to provide a
method and apparatus for producing gears by a rolling operation in
which the displacement of metal into the tooth form is controlled
to eliminate or substantially eliminate the formation of a "cold
shut."
Other objects and features of the invention will be more apparent
when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view showing the formation of "rabbit
ears" in a rolled gear.
FIG. 2 is a diagrammatic view illustrating the dies and their
arrangement for the rolling of gears.
FIG. 3 is a fragmentary sectional view on the line 3-3 of FIG.
2.
FIG. 4 is a diagrammatic view illustrating a sequence of sectional
views perpendicular to the axis of a die showing the shape of the
teeth.
FIG. 5 is a diagrammatic view illustrating initial, intermediate,
and final tooth form of the blank.
FIG. 6 is a fragmentary elevational view of the die.
FIG. 7 is a fragmentary edge view of the die.
FIG. 8 is a fragmentary sectional view on the line 8-8, FIG. 6.
FIGS. 9 and 10 are fragmentary sectional views showing
modifications of dies.
DETAILED DESCRIPTION OF THE INVENTION
In the production of gears or other toothed members by means which
result in the flow of metal from tooth spaces of the gear into the
teeth, there is a tendency for the metal to follow the path of
least resistance and initially, to be displaced locally into
projections next adjacent to the sides of the tooth spaces as they
are formed. As more and more material is displaced from the tooth
space these local projections reach substantial dimension. They are
referred to as "rabbit ears."
Referring first to FIG. 1 there is shown an intermediate stage in
the production of a gear by a rolling operation in which opposed
rolls are fed radially into a rotating blank. Here it will be
observed that metal has been displaced from an initial outside
diameter indicated at 10 to form recesses 12 which are the
beginnings of the tooth spaces between the teeth of the gear. The
teeth during this stage of the process are indicated generally at
14, and teeth in different stages of formation are specifically
designated 14a, 14b, 14c and 14d. It will of course be understood
that as more and more metal is displaced from the tooth spaces 12,
this metal will flow into the teeth and will be shaped by the
coacting flanks of the teeth of the rolling die into the desired
configuration such for example as an involute form.
The tendency of the metal displaced from the grooves or recesses 12
to follow the path of least resistance results in the formation of
localized projections 16a which are referred to as "rabbit ears."
As the rolling operation continues and more and more material is
displaced from the spaces 12, the teeth grow in height as indicated
at 14b, 14c and 14d. As indicated at 14b the "rabbit ears" here
designated 16b, are substantially higher than as indicated at 16a
and the tooth 14b is beginning to assume a required shape, as for
example an involute shape. The tooth designed at 14c is the result
of still further displacement of metal from the groove 12 into the
tooth form and here it will be observed that the "rabbit ears" 16c
are being forced toward each other and into contact. In the final
tooth form these "rabbit ears" have been forced together into
contact with each other but without establishing a homogeneous
material at the crests of the teeth. This produces what is known as
a "cold shut," here designated at 18, and this represents a
weakening of the tooth which in the past has required removal of
the crests of the teeth by grinding or cutting to, for example, an
outside diameter designated at 20, which simply eliminates the
portion of the tooth in which the "cold shut" is present.
According to the present invention, a gear blank 22 is provided
which as illustrated is provided with a central hole 24 for the
reception of a support arbor. A pair of dies 26, 28 are provided,
the axis of which, as indicated at 30, are parallel and establish a
plane containing these axes which also contains the axis of the
blank 22 during the rolling operation. Subsequently, the exact
tooth form of the dies 26, 28 will be described in some detail, but
for the moment it will be observed that the teeth 32 of the dies,
which for the time being may be considered as identical, are
longitudinally tapered. Specifically, the teeth 32 have outwardly
tapered crests 34 and inwardly tapered roots 36. This taper or
inclination is of course with respect to the axis of the die. In
general, it may be said at this point that the shape of the spaces
between the teeth 32 and particularly at and adjacent the roots
thereof, have a configuration so that any "rabbit ears" tending to
be formed by the entry of the crests of the teeth of the die into
the blanks engages these surfaces and hence, the formation of the
"rabbit ears" is prevented. Instead, the displaced material is
caused to flow toward the centerline of the teeth.
The portion of the dies 26, 28 at the left hand edge thereof, as
seen in FIG. 2, is cylindrical and is adapted to engage or closely
approach the smooth cylindrical outer surface of the blank 22.
In order to carry out the operation the dies 26 and 28 are rotated
in the same direction through positive acting gearing which
maintains the dies 26 and 28 in exactly properly timed
relationship. This relationship is such that if the gear has an
even number of teeth, centerlines of teeth on the dies 26 and 28
simultaneously pass through the plane containing the axes of the
dies. If the blank contains an odd number of teeth, the centerline
of a tooth on one of the dies 26 or 28 passes through the plane
containing the axes of the dies while a plane bisecting the tooth
space of the other die is passing through the same plane.
A loading chute indicated diagrammatically at 40 is provided
receiving a number of blanks 22. The foremost blank is advanced
from the chute by suitable means into a locator in alignment with a
blank supporting arbor 42 having a reduced portion 44 adapted to
fit snugly within the hole 24 in the blank and defining a shoulder
46 engageable with the end or side of the blank. Suitable power
means are provided for advancing the arbor 42 axially through the
space between the dies. As soon as the blank 22 is engaged by the
smooth cylindrical adjacent ends of the dies, or alternatively,
when its advancing edge is engaged by the tapered crests 34 of the
die teeth, rotation will be imparted to a blank 22 in properly
timed relation to the rotation of the dies. As the blank is
advanced material is displaced by the tapered crests of the teeth
of the dies into the appropriately tapered root spaces thereof
while the formation of "rabbit ears" is prevented as previously
suggested.
When the completed gear has passed beyond the dies 26 and 28 a
stripper 48 mounted on a support 50 is inserted behind the finished
gear, here designated 22a and the arbor 42 is retracted.
The actual operation is carried out with the dies 26 and 28 rotated
at substantial speeds, preferably the speed of rotation being such
as to produce a surface speed approximately 130 feet per minute.
The arbor 42 is advanced at a rate which depends upon the material
of the blanks, the diameter thereof, and other considerations.
However, it has been found that satisfactory results have been
obtained when the rate of advance is approximately 17 inches per
minute.
The teeth of the dies 26 and 28 may be modified to have the teeth
of a final short section untapered to produce a finishing action on
the teeth of the gear. Alternatively, it may be desirable to
provide separate finishing dies having unmodified teeth for
finishing the gear as it emerges from the tapered toothed dies 26
and 28. These finishing dies may be abutted against the sides of
the rolling dies or separated therefrom. With this arrangement the
axial advance of the blank may be speeded up.
The design of the roll dies and the initial diameter of the work
blank are critical factors determining the success or failure of
this operation. Inasmuch as the blank is driven in rotation solely
by its engagement with the rolling dies, it is essential to provide
an initial diameter on the blank as determined by the
circumferential pitch of the teeth of the dies measured at the
minimum tooth crest diameter such that the initial impression made
by a tooth of one die will be timed so as to register accurately
with a tooth of the opposite die after the initial rotation of
180.degree.. On the other hand, it is elementary that, disregarding
material displaced axially beyond the ends of the original blank,
all of the material displaced from the tooth spaces appears in
material which in the finished gear, lies outwardly of the initial
outside diameter. It is of course appreciated that the exact
material displaced from a tooth space does not necessarily appear
in the outer portion of a tooth. Instead, material may be displaced
toward the midplane or centerline of a tooth resulting in generally
radially outward flow of other material beyond the original outside
diameter of the gear. The original outside diameter of the gear
thus in general constitutes the rolling or generating diameter
which may or may not coincide with the nominal pitch diameter of
the gear. Accordingly, the rolling die is designed by first
determining the required full tooth configuration of the gear,
thereafter determining a blank diameter such that the
cross-sectional area of the tooth spaces within the diameter shall
be approximately equal to the cross-sectional area of the tooth
form lying radially outwardly of the diameter. With this
determined, the next step is to design a roll with an appropriate
number of teeth of proper configuration and with the tooth space
configuration designed as to the root surfaces and flank surfaces
adjacent the root so as to substantially completely prevent
formation of "rabbit ears" and to cause material displaced by the
teeth of the rolling dies to cause a flow of material toward the
centerlines of the teeth, thus preventing formation of "rabbit
ears".
The design of the die rolls is critical. If insufficient space is
left for the controlled flow of material into the tooth formation
of the gear by reason of insufficient tooth space formed in the
die, excessive pressures result. On the other hand, if excess
space, and particularly space adjacent the edges of the tooth
spaces of the gear during the generating operation is present, then
the "rabbit ears" form and having once formed cannot thereafter be
eliminated.
As stated before, the exact shape of the tooth space between
adjacent teeth of the die particularly, the exact shape or
configuration of the root portion thereof, is not critical except
at the ends of the teeth where the final formation of the teeth of
the work gear occurs. Accordingly the configuration of the root
portions of the teeth of the die, in sections adjacent the entry
end of the blank, may include inclined portions engageable
initially by material tending to flow into the formation of "rabbit
ears" and terminating in a channel formed by the intersection of
these inclined surfaces or in a proper case, by a separate channel
intermediate the inclined surfaces into which flow of displaced
material occurs as it is displaced along the inclined surfaces
toward the midplane of the gear teeth.
While the foregoing describes an operation employing roll dies of
particular form which, when designed with maximum perfection
completely eliminates the "cold shut" heretofore present in roll
gears, it is to be understood that the present method may be
practiced with die rolls which merely reduce the formation of
"rabbit ears" and the consequent "cold shut" so that the finished
rolled gear may exhibit a superiority over present rolled gears
only in the fact that a "cold shut" at the crests of the teeth
thereof is of a reduced amount. In this case, as heretofore, a
certain amount of material at the crests of the teeth may be
removed to remove the "cold shut" although with the practice of the
present invention this removal will be of less material. With this
occurring, it is of course necessary to select the initial roll
diameter in accordance with the final desired tooth configuration,
taking into account the fact that the final operation will remove a
predetermined amount of material at the crests of the teeth.
Referring now to FIGS. 5--7 there are shown detailed views
illustrating the shape of the teeth of the gear rolling dies. In
FIG. 6 the die proper is designated 60 and it is provided with a
multiplicity of teeth 62 separated by tooth spaces 64. The teeth 62
taper and more specifically, have a tapered crest 66 inclined
outwardly from the smaller side of the die and thus giving the die
an overall generally conical configuration. In these FIGS. the
taper imparted to the gear teeth, both to the crests and roots
thereof, as well as the chordal thickness of the teeth, is
exaggerated for clarity. The bottom of the tooth spaces or roots 68
are inclined oppositely from the inclination of the crests 66 of
the teeth. It will be observed that at the small end of the cutter
the periphery is essentially an uninterrupted circle 70. This
circle constitutes the rolling diameter of the die and hence, of
the gear produced thereby. This diameter on the gear will be
adjacent but not necessarily coincident with the pitch diameter of
the finished gear.
The taper of the teeth is preferably arranged so that any lead
check measured along a side of a tooth and along a line parallel to
the axis of the tooth or measured at constant radial distance from
the axis of the die, will show the same lead at both sides of the
teeth. In the illustrated die shown in FIGS. 5--7 the teeth, for
simplicity, are shown as spur teeth. However, helical teeth will
conform to the same requirements and the lead or helix angle at
opposite sides of the teeth, measured along lines equidistant from
the axis will be the same on both sides of the teeth.
For convenience and clarity, reference characters are applied to
like portions of the teeth in accordance with the following
description: The crests of the teeth are constituted by the areas
72. The sides or flanks of the teeth are constituted by the areas
74. The areas at the roots of the teeth are designated 76. The
chordal thickness of the teeth measured on the rolling diameter 70
is uniform from end to end of the teeth and is equal to the uniform
chordal spacing between adjacent tooth surfaces measured on this
diameter.
Referring now to FIG. 4 there is diagrammatically shown in a single
view the progression in the cross-sectional shape of the gear
rolling die and particularly, the toothed portions thereof. In this
FIG. the shape of a tooth and tooth space as viewed in a diametral
plane adjacent the inlet side of the die, as for example at the
plane designated A in FIG. 2, is illustrated in FIG. 4 where the
tooth is designated 80a and the tooth space is designated 82a. The
circular arc 84 represents the smooth continuous circular outside
diameter of the dies at the inlet end where the teeth 80 terminate.
It will be observed in FIG. 4 that the angular dimension of the
tooth 80a is substantially equal to the angular extent of the
recesses 82a. Moreover, the height of the tooth portion 80a is
approximately equal to the depth of the tooth space 82a. With this
arrangement the material displaced by the tooth section 80a is
adapted to be received in and substantially fill the tooth spaces
82a. Moreover, it will be observed that the root surfaces 86a of
the tooth spaces 82a are in position to be engaged by "rabbit ears"
as they tend to be formed adjacent the sides of the tooth space
produced by the tooth 80a. As illustrated in FIG. 4, the root
surfaces 86a and the adjacent side surfaces of the tooth space
prevent formation of "rabbit ears" and guide the flow of displaced
material toward the middle portion of the tooth space intercepted
by the radial line 88a.
Instead of providing a substantially circumferential root surface
82 a, it is within the contemplation of the present invention to
provide a root surface such as illustrated at 89a which causes all
of the metal displaced by the tooth to be guided toward the metal
portion of the tooth space. In this case not only is there an
elimination of "rabbit ears," but the metal is not permitted to be
displaced at the extreme side of a tooth space. Instead, all of the
material is displaced centrally. The only requirement at this time
is that the root surfaces between the teeth of the rolling die do
not permit the growth of "rabbit ears" and it is quite satisfactory
to displace all of the metal toward the central portion of the gear
teeth at this stage of formation.
At a radial section further across the width of the die, the height
of the die teeth have increased, as indicated at 80b, and
correspondingly the depth of the space between adjacent teeth has
increased as indicated at 82b. Again, the requirement is observed
that the depth of the tooth space below the rolling diameter 84 and
its configuration shall be such as to receive all of the metal
displaced by the die tooth 80b. Further, it is a requirement that
the root surface 82b shall be located in position to cause a flow
of metal displaced by the tooth 80b toward the middle portion of
the gear teeth.
Similarly, a further section through the die 26, as for example at
C, indicates a tooth 80c whose crest is substantially higher than
the crest of the same tooth at the section B. Similarly, the depth
of the tooth space has increased so that the root surface 82c is as
shown. Again, the arrangement is such that the cross-sectional area
of the tooth space below the rolling diameter 84 shall be equal to
the cross-sectional area of the tooth 80c above the rolling
diameter within suitable limits. It will be observed that the tooth
80c has begun to assume recognizable involute form.
Finally, adjacent the outlet side of the die 26 the die tooth
assumes the shape illustrated at 80d and the root surface is
located at 82d. This represents substantially a tooth form
conjugate to the desired tooth to be produced on the gear.
In the foregoing the fact that some metal may be displaced axially
of the blank has been ignored. In practice where axial flow of
metal occurs and the amount of such flow can be predicted, the die
design will be modified so that less cross-sectional area will be
required below the rolling diameter because of the fact that not
all of the metal displaced by the tooth portion above the rolling
diameter is displaced into the tooth space.
In this illustration it will be observed that in cross sections
A,B,C and D through the die 26, the chordal thickness of the tooth
at the rolling diameter remains constant throughout, as does the
chordal spacing between adjacent teeth on the rolling diameter.
Referring now to FIG. 5 there is diagrammatically illustrated the
generation or formation of teeth on a solid blank 90. It will of
course be understood that where the blank 90 is referred to as
solid, this does not eliminate the possibility of a central hole
such as the hole 24 illustrated in FIG. 2. It does require the
formation of teeth in their complete form from material provided in
a blank having initially a smooth cylindrical surface. In this FIG.
the width of the die is designated by the arrow 92 and the solid
blank 90 as it engages the left-hand end of the die has a smooth
circular or cylindrical outside diameter 94. It is understood that
the work gear 90 as it progresses is moved in a direction parallel
to its axis and the diagrammatic showing of FIG. 5 is merely to
indicate the growth of the circle containing the crests of the
teeth and the diminution of the circle containing the roots of the
teeth as the work gear is advanced axially from one side to the
other of the die. The work gear at the position 90a has had its
peripheral portion formed so that the circle 94a contains the
crests of the partially formed teeth and the circle 96a contains or
is tangent to the roots of the teeth as partially formed at such
time.
When the blank has advanced to the position indicated at 90b the
crests of the partially formed teeth are contained in the circle
94b, and the circle 96b contains or is tangent to the roots of the
teeth.
When the gear emerges beyond the outlet end of the die or dies as
illustrated at 90c, the teeth have been formed such that the circle
94c contains the crests of the teeth and the circle 96c contains or
is tangent to the root surfaces thereof.
It will be observed by comparing construction lines 97 and 98 with
the reference line 99 that the increase in height of the gear teeth
above the rolling diameter which corresponds to the line 99, is
equal or substantially equal to the increase in the depth of the
tooth space below the rolling diameter. Moreover, as suggested on
this FIG., the increase in height of the crests of the teeth
progresses substantially uniformly and equally with the increase in
root depth.
The foregoing describes a rolling die which has been satisfactorily
used in pairs to produce gears from solid material as described in
the foregoing. However, it is appreciated that the precise tooth
form of the actual dies which have been tested in practice is not
critical. The single essential requirement is that the teeth shall
be tapered from end to end both to have an increasing tooth height
as well as an increasing depth of space between the teeth, and
further, that the configuration of the surfaces defining the space
between the teeth of the die shall include surfaces in position to
intercept the material of the blank which would otherwise be
displaced locally into "rabbit ears," and effective to cause this
material to flow inwardly toward the center of the gear tooth as it
is being formed by metal displaced from portions of the blank which
are to become tooth spaces in the finished gear.
While the foregoing specific disclosure has been of an arrangement
in which the axes of the dies are parallel to each other and are
parallel to the axis of the blank, it will be apparent that the
invention is applicable also to an arrangement in which the dies
are designed to operate with their axes crossed with respect to the
axis of the gear. In this case it will of course be understood that
the axes of the dies are crossed with respect to each other at an
angle double the angle at which the axes of the individual dies
cross with respect to the axis of the gear.
In the embodiment of the invention so far described the increase in
crest height of the die teeth and the decrease in root diameter of
the die teeth are substantially equal from end to end and are at a
constant rate.
Referring now to FIG. 9 there is illustrated a different embodiment
of the invention in which the die 100 has teeth 102, the crests 104
of which are of curved configuration from the small end toward the
large end of the teeth. In this embodiment, the root diameter 106
is illustrated as of uniformly decreasing diameter.
The embodiment of the invention illustrated in FIG. 10 is generally
similar. In this case the die 110 has the teeth 112 the crests 114
of which increase at a diminishing rate from the small end toward
the large end, thus producing the curved configuration illustrated
in the FIG. In this embodiment of the invention the root diameter
116 of the teeth increases at a diminishing rate generally
corresponding to the increase in rate of the crest diameter.
These embodiments of the invention permit a variation in
controlling the flow of material and in general, produce a more
substantial rate of flow during initial formation of the teeth with
a diminishing rate of flow as the teeth of the blank are formed
into their final configuration.
The dies disclosed herein and the method of their use in rolling
gears from cylindrical blanks (as opposed to finish rolling)
represents a significant advantage over the dies and type of
rolling in which opposed dies are moved radially into a blank
having an initial outside diameter approximately equal to the pitch
diameter, because in this case the blank diameter is initially
contacted by the die roll or die teeth at approximately the pitch
diameter thereof, and therefore the operating conditions for this
method are virtually similar to those of present finish rolling of
substantially fully cut teeth. In other words, because starting
diameter of rolls is the pitch diameter, the circular pitch of the
roll and gear are nearly identical.
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