Gear and shaft and forming method thereof

Abstract: A method for producing a unitary toothed part with a shaft and the resulting products. In the process, a blank (1) is formed. The blank includes a shaft part (9b) and a flange part (1a). The flange part having a thicker outer diameter and a thinner inner diameter. The outer diameter is formed into a tubular part (2a) by drawing. A plurality of teeth (3d) and remnants (3f) are formed by extruding the tubular part. At least one spline (3e) is formed by extruding the shaft part. Through the steps of forming, drawing, and extruding, a blank is made into a unitary part (3) having teeth and a shaft thus increasing precision, rigidity, durability, and reducing forming costs.

Description: The present invention relates to a high precision toothed component, or gear, having a shaft and a method of molding therefor. Such components are frequently used within the automatic transmissions of automobiles. In conventional methods for forming a gear with a shaft, the shaft part and the flange part of the gear are difficult to mold or form as a unit. In a known method, a shaft part and a flange part are molded separately, and then welded together afterwards. This method requires anti-carburizing and pre-processing of the molded parts before welding. This method also requires a separate jig for holding the parts during welding. Since heat is used in this method, there are associated heat deformation problems resulting in precision losses and high production costs. DE 19723073 discloses the formation of a toothed article from a single sheet metal disc. The method used is a complex multistep process including many conversion and processing steps followed by heat treatment and more conversion and pressing routines and subsequent folding before forming a groove or toothing. An alternative known method for forming this type of gear with a shaft is described with reference to Figures 6(A) and 6(B). In this third method, the gear part and shaft are molded from an initial unitary object. In this method, a raw material blank or billet 20 is formed in to an intermediate product 21. The raw material billet 20 comprises a disk-shaped flange part 20a and a cylindrical shaft part 20b. A tubular part 21a and a bottom part 21b are formed by backwards extruding the flange part 20a. Upon completion of the backwards extrusion the intermediate product 21 is formed but requires further complex processing before reaching a final form. This third method requires very high pressure to achieve the backwards extrusion of flange part 20a. Due to the high extrusion pressure, the life span of the extrusion die is short and the cost for construction for the die and other extrusion equipment is high. The high extrusion pressures also requires the intermediate product 21 to have an undesirable thick bottom or disc part 21b and tubular part 21a. The backwards extrusion method has a poor net shape rate result and production losses are high due to non-conformity of the extruded product with required dimensions for example. This molding method is also difficult to apply to large parts. There is a requirement to provide a high precision method of molding. There is another requirement to provide a method of molding a toothed part with shaft that has high precision. There is a further requirement to provide a toothed part with shaft that has high precision, high rigidity, and strength. There is an additional requirement to provide a method of molding a toothed part with hollow shaft and a flange constructed from a bottom part. There is a further requirement to provide a method of molding a tubular part ,or a flange constructed from a tubular part, and disk part. There is another requirement to provide a method of molding teeth on a tubular part or on a shaft. There is also a requirement to provide a combination of plastic working steps in a method for producing a final product with precise dimensions and low loss rates. It is to be understood that the word plastic, or plastic working applies to the material being malleable or deformable during a working process and does not require a carbon material, or any other specific material, to be used with the method. Briefly stated an aspect of the present invention relates to a method for producing a unitary toothed part and a shaft according to claim 1. According to a preferred embodiment of the invention, in the process, a blank is formed. The blank includes a shaft part and a flange part. The flange part having a thicker outer diameter (radially outer part) and a thinner inner diameter (radially inner part). The outer diameter is formed into a tubular part by drawing. A plurality of teeth and remnants are formed by extruding the tubular part. At least one spline is formed by extruding the shaft part. Through the steps of forming, drawing, and extruding a blank is made into a unitary part having teeth and a shaft thus increasing precision, rigidity, durability, and reducing forming costs. The method may further comprise the steps of: forming the flange part into a large diameter part and a small diameter part, the large diameter part being a first portion and larger than and concentric to the small diameter part, and the large diameter part being thicker than the small diameter part, and forming a plurality of remnant parts by extruding said tubular part, the remnant parts between the tubular part and the shaft part interposed with the plurality of teeth. The method may further comprise the steps of drawing an outer annular portion into said tubular part generally parallel to said shaft part, said flange part bemg a disk generally perpendicular to an axis of said shaft part, said disk having said outer annular portion, said outer annular portion being thicker than a remainder of said disk, and the teeth portions being formed on one of an inner and outer surface of the tubular part whereby the greater thickness of the tubular part permits formation of the teeth portions while retaining substantial strength. The step of drawing the tubular part may comprise drawing said flange part into said tubular part and a bottom part. In the method of forming a toothed part with a shaft, forming a flange part and a shaft part may be conducted by cold forging. In the method of forming a toothed part with a shaft, preferably the flange part includes a large diameter part and a small diameter part, the large diameter part having a thickness greater than a thickness of the small diameter part. In the method of forming a toothed part with a shaft said teeth portions may be rigid. Various embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Fig. 1(A) is a cross-section view of a raw material blank or billet. Fig. 1(B) is a cross-section view of an intermediate product formed from the blank of Figure 1(A); Fig. 1(C) is a cross-section view of a molded product formed from the intermediate product of Figure 1(B). Fig. 2 is an end view of the molded product of Figure 1(C), in the direction left to right in the drawing. Fig. 3 is a cross-section view of a final product formed from the molded product of Figure 1(C); Fig. 4(A) is a cross-section view of a raw material blank or billet; Fig. 4(B) is a cross-section view of an intermediate product formed from the blank of Figure 4(A); Fig. 4(C) is a cross-section view of a molded product formed from the intermediate product of Figure 4(B). Fig. 5 is an end view of a molded product of Figure 4(C), in the direction left to right in the drawing; Fig. 6(A) is a process diagram of the prior art, and, Fig. 6(B) is a process diagram of the prior art. Referring now to Figs. 1(A) and 1(B), a malleable raw material billet or blank 1 includes a disk-shaped flange part 1a, and a tubular shaft part 1b. A radially outer part of the flange 1a has an axial thickness dimension t2, and a radially inner part has axial thickness dimension t1. The tubular shaft 1b has a radial thickness dimension t3. The thickness dimension t2 of the radially outer part of flange 1a is larger than the thickness t1 of the radially inner part. It is to be understood, that while the raw material blank 1 is the precursor to the later formed intermediate part 2 of Figure 1(B), the size, shape, and thickness of the flange part 1a and the shaft part 1b are selected to allow easy formation of the later formed intermediate product 2. It is to be understood that the raw material billet or blank 1 may be formed by many forming methods common in the field, but that cold forging is a commonly used and economic method since heat forging acts to abrade the forming mold and reduce precision. According to a first arrangement, intermediate product 2 is formed from the raw material billet or blank by drawing flange part 1a. The intermediate product 2 also includes a tubular shaft part 2c and a flange. The flange includes a radially outer tubular part 2a and a disc part 2b which extends radially between the shaft 2c and tubular part 2a. During forming of the blank 1, the radially outer part of the flange 1a is molded thicker than the radially inner part. The raw material billet or blank 1 is designed so that, in addition to having a thinner disc part 2b, the material of the intermediate product 2 flows easily, and with lower die loads, that is to say, the flange 1a is readily deformed to form the disc 2b and tubular part 2a of the intermediate product. The formation of the raw material billet or blank 1, with the specified and shaped flange part 1a, enables the desired thickness of the tubular part 2a to be readily obtained with lower processing loads. It is to be understood, that the thickness t1 of the radially inner part and thickness t2 of the radially outer part are determined according to the desired shape, configuration and/or other properties of the final product, the loads acting upon the forming die, considerations for additional material to form intermediate products with differing outer dimensions, or other factors. Since thickness t1, t2, and t3 are selectable, according to intermediate and final product requirements, a wide variety of final products may be manufactured using this method. Referring additionally to Figures 1(C), 2, and 3, the intermediate product 2 is molded in a desired manner to form a molded product 3. The molded product 3 includes an axial shaft part 3c extending from a radial flange which includes a disc part 3b and a tubular part 3a. Teeth 3d, formed from part of the material of tubular part 2a, are molded along the outer portion of the tubular part 3a and disc part 3b. The teeth 3d are moulded in a shape, pitch, and frequency according to specific manufacturer or customer requirements. An extrusion remnant 3f is formed by extrusion of the intermediate product in the region between the disc 3b and tubular part 3a. The remnant improves the rigidity and strength of the teeth 3d by increasing the stiffness of the molded product in the region of the teeth 3d. A spline 3e is formed on the radially outer shaft 3a, during molding of shaft part 2c for use in later assembly. After molding, the molded product 3 of Figure 1(C) may be further processed by cutting, punching a hole for lubrication oil, or other manufacturing steps, to form a final component such as that shown in Figure 3. The final component 4 of Figure 3 is assembled with bushings 6, and/or with other application specific items (not shown) so that the molded product 3 constitutes part of an assembled product 4 with teeth parts 5. Referring additionally now to Figs. 4(A), 4(B), 4(C), and 5, a second arrangement is shown for a molding process to form a toothed part with a shaft. A raw material billet or blank 11 is constructed from a disk-shaped flange part 11a and a tubular shaft part 11b extending from flange part 11a. The flange part 11a includes a radially outer part, having a thickness dimension in the axial direction of the disc t12 and a radially inner part having a thickness dimension in the axial direction t11. Thickness t11 is less than thickness t12. The shaft part 11b has a thickness dimension t13 in the radial direction of the shaft. An intermediate product 12 (Figure 4B) is formed by drawing flange part 11a of the billet or blank 11. The intermediate product 12 is includes a radially inner tubular shaft part 12c extending from a flange part 12b. The flange 11a of the raw material billet 11 forms a radially outer tubular part 12a parallel to shaft part 12c, and a disk part 12b, generally perpendicular to shaft part 12a and 12c. As described above, the radially outer part of flange part 11a is thicker than the radially inner part of flange part 11a. It is to be understood, that the thicknesses of the radially inner and outer parts are selected in accordance with considerations including requirements to provide a thin disk part 12 of the final product, the loads acting on the forming die, requirements for additional material for subsequent machining, and other factors. The thickness of these parts is further selected to enable the material to readily flow in molding, with smaller loads, and still obtain the desired thickness of tubular part 12a. Since thickness t11, t12, and t13 are selectable, according to intermediate and final product requirements, a wide variety of final products may be manufactured using this method that is to say, the load acting on the die is smaller than in known methods and various intermediate products with differing outer diameters for the tubular part 12a can be readily obtained from the same raw material blank or billet 11. The molded product 13 of Figure 4(C) is formed by forming teeth on the radially outer tubular part 12a and by forming a spline on the shaft part 12c. The molded product 13 includes a shaft part 13c and a flange comprising a disk part 13b and a tubular part 13a. Teeth 13d are formed in the inner perimeter part of the tubular part 13a, opposite the spline 13e on the radially outer surface of the shaft part 13c. The teeth 13d are formed by extruding tubular part 12a. An extrusion remnant part 13f is present near disk part 13b opposite shaft part 13c. The extrusion remnant part 13f improves the rigidity and strength of the teeth 13d. The molded product may be further machined through cutting or through punching holes for lubrication oil, such that the molded product 13 becomes a final product or component. In another arrangement, cold forging allows a manufacturer to form the raw material billet or blank 11 with precision. If the raw material 11 were formed with heat forging, the forming die would abrade, precision would be limited, and die life would decrease. It is to be understood, that according to either arrangements, a high precision toothed part such as an inner or outer gear with a shaft may be formed from a unitary body with high precision, without welding. It is to be understood, that according to either arrangement concerning the method of forming a toothed part with a shaft, the resulting toothed part with a shaft is an additional third and fourth arrangement with either the tubular part facing away from the shaft or forming a cylinder about the shaft. It is to be further understood, that by devising the thickness for the flange parts of the raw material and by forming the flange of the intermediate product by drawing, the load acting on the die is minimized. It is to be further understood, that since the load acting on the die is small the life span of the die is correspondingly increased. It is to be further understood, that using the arrangements herein described, a manufacturer may achieve improved near net shape rates, high rigidity and durability, and minimize production costs. It is to be further understood, that by forming teeth and a remnant part, according to the above arrangements, the strength and rigidity of the gear is improved. Having described preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope of the invention as defined in the appended claims.

Claims: A method for forming a toothed part with a shaft, comprising the steps of: forming a raw material blank (1), said blank including at least a shaft part (1b) and a flange part (1a), said flange part coaxial and perpendicular to said shaft part; drawing a tubular part (2a) on said flange part parallel to and away from said shaft; extruding a plurality of teeth portions (3d) on a surface of said tubular part; and characterised by the subsequent step of extruding at least a first spline (3e) on the outer surface of said shaft part. A method for forming a toothed part with a shaft, according to Claim 1, wherein the step of forming a raw material blank comprises forming said flange part into a large diameter part and a small diameter part, said large diameter part being a first portion and larger than and concentric to said small diameter part, and said large diameter part being thicker than said small diameter part; the method further comprising the step of: forming a plurality of remnant parts (3f) by extruding said tubular part, said remnant parts interposed with said plurality of teeth and between said tubular part and said shaft part. A method for forming a toothed part with a shaft, according to Claim 1, wherein said flange part of said raw material blank is a disk generally perpendicular to an axis of said shaft part; said disk having said outer annular portion, said outer annular portion being thicker than a remainder of said disk; and further comprising the steps of: drawing said outer annular portion into said tubular part generally parallel to said shaft part; and forming said teeth portions on one of an inner and an outer surface of said tubular part, whereby the greater thickness of said tubular part permits formation of said teeth portions while retaining substantial strength. A method for forming a toothed part with a shaft, according to Claim 1, wherein said step of drawing said tubular part comprises the step of: drawing said flange part into said tubular part and a bottom part. A method for forming a toothed part with a shaft, according to Claim 4, wherein: said flange part of said raw material blank includes a large diameter part and a small diameter part; and said large diameter part having a thickness greater than a thickness of said small diameter part. A method for forming a toothed part with a shaft, according to Claim 5, wherein said step of forming said raw material blank with said flange part and said shaft part is conducted by cold forging. A method for forming a toothed part with a shaft, according to Claim 1, whereby said teeth portions are rigid.

Inventors: ISHINAGA NOBUYUKI, KANAMARU HISANOBU, SUZUKI TOSHIO, ISHINAGA, NOBUYUKI, KANAMARU, HISANOBU, SUZUKI, TOSHIO
Applicants: AIDA ENG LTD, BRYER KENNETH ROBERT, AIDA ENGINEERING CO., LTD., BRYER, KENNETH ROBERT
Application year: 2001
Main classification: B21K1
IPC codes: B21K1, B21K23, F16H55, B21J5