Abstract: An apparatus and method are provided for the thermomechanical net shape finishing of precision gear tooth surfaces by controlled deformation into metastable austenitic condition. To this end, an arrangement of a fixed axis through-feed motion of workpiece and moving axes in-feed motion of two opposed rolling dies are utilized. By means of process control methods and architecture for accomplishing precision mechanical motions, thermal and environmental control and timely and automatic transfer of workpiece, high strength and high accuracy gear tooth contact surfaces are produced.

Abstract: An apparatus and method are provided for the thermomechanical net shape finishing of precision gear tooth surfaces by controlled deformation into metastable austenitic condition. To this end, an arrangement of a fixed axis through-feed motion of workpiece and moving axes in-feed motion of two opposed rolling dies are utilized. By means of process control methods and architecture for accomplishing precision mechanical motions, thermal and environmental control and timely and automatic transfer of workpiece, high strength and high accuracy gear tooth contact surfaces are produced.

Abstract: An apparatus is disclosed for performing thermomechanical processing of gears in which precise control of the thermal, metallurgical and mechanical action during the forming process is maintained. The apparatus comprises an induction heating system which reaustenitizes the surface of the gear with minimum decarburization, a material transfer system which provides timely operations on the work piece, tooling and fixture adjustments which provide accurate initial conditions for forming, and a process control architecture that provides the precise sequence and timing necessary to achieve metallurgically sound and dimensionally accurate gears. The induction heating cycle can be controlled from the peak, average or minimum gear surface temperature detected with a high response optical pyrometer. An inert environment is maintained around the workpiece during the induction heating and transfer to quenching above the M.sub.s temperature.

Abstract: For quenching heated metallic work pieces with a quenching intensity that lies in the region of H values from 0.2 to 4, which is typical for oil or water quenching, a cooling gas is used as the quenching medium in the form of discrete jet streams issuing from a nozzle field and impinging on the work piece surface to be cooled. With limiting of the blower power for the cooling gas serving a predetermined maximum limit of about 1000 kW per square meter of nozzle field the quenching intensity, with suitable selection of gas jet parameters, in particular the gas velocity w, the gas pressure p, the gas jet cross-section and the number of impinging jets per unit of surface is brought to an H value between 0.2 and 4.

Abstract: A method and press for uniformly quenching a heated annular workpiece while fixturing the workpiece to prevent distortion during quenching. The press has a conically shaped lower die for receiving a workpiece to be quenched thereon and a vertically reciprocable conically shaped upper die for clamping and fixturing a workpiece between them. The press has a generally cylindrical quench ring carried by the upper die for engaging against the lower die to form a chamber around the workpiece to immerse the workpiece in quenching fluid. The lower die has a plurality of spaced apart inlets for uniformly distributing quenching fluid around the workpiece and which are preferably angled relative to the center axis of the lower die for producing a swirling turbulent flow of fluid within the chamber to more rapidly and uniformly quench the workpiece.

Abstract: An apparatus is disclosed for performing thermomechanical processing of gears in which precise control of the thermal, metallurgical and mechanical action during the forming process is maintained. The apparatus comprises an induction heating system which reaustenitizes the surface of the gear with minimum decarburization, a material transfer system which provides timely operations on the work piece, tooling and fixture adjustments which provide accurate initial conditions for forming, and a process control architecture that provides the precise sequence and timing necessary to achieve metallurgically sound and dimensionally accurate gears. Using this invention the induction heating cycle can be controlled from the peak, average or minimum gear surface temperature detected with a high response optical pyrometer. An inert environment is maintained around the workpiece during the induction heating and transfer to quenching above the M.sub.s temperature.

Abstract: A universal quench press is used for the precision quenching of gears, bearing rings, saw blades, slitting knives, cylindrical parts, flat parts, dished parts, and other articles. A set of quenching dies reduce or eliminate the distortions in size, roundness, taper, and flatness encountered in manufacturing processes prior to the press quenching process and/or operation. The press has a plurality of posts or tie-rods configured to distribute the forces of the applied loads uniformly. Provisions are made for a plurality of generally concentric rams with all of the rams powered by hydraulic or pnuematic cylinders or other force exerting device or devices to provide a uniform and evenly distributed force. An automatic quench media splash guard seals the quenching chamber during operation and requires absolutely no set-up or operating adjustments or changes.

Abstract: A die quench press for hardening gears and other generally circular parts is disclosed. The press has a horizontal die which generally comprises a plurality of segments movable radially inwardly and outwardly. The upper die portion of the press rotates into a vertical position for easy insertion of parts to be quenched.