Abstract: A manufacturing method for a toothed member includes a thickened tooth shaping process in which a toothed shape is formed on a side wall portion while making a thickness of the side wall portion larger than a thickness of a bottom surface portion by relatively moving the compression die with respect to the restraint die and the pressure receiving member in the axial direction from the side of the opening end of the cup-shaped raw material toward the bottom surface portion. The manufacturing method being such that the thickened tooth shaping process includes applying a load against the restraint die such that the restraint die restrains the first surface and the second surface.

Abstract: A novel method of manufacturing a toothed disc is taught wherein the teeth can be cold formed to a relatively high set of tolerances in a relatively time-efficient manner. A cold-formed disc blank with an annular thickened ring about its periphery is forced through a set of tooth forming rollers which engage the annular thickened ring. As the blank is forced through the set of rollers, the rollers cold forming tooth structures in the annular ring. In some circumstances, the tooth structure can be a final desired tooth profile and in other circumstances, the disc blank may be forced through two or more different sets of tooth forming rollers, each set of tooth forming rollers contributing to the forming of the final, desired tooth profile.

Abstract: A method of manufacturing a helical gear, includes a gear cutting process for forming a roughly-processed gear by applying a gear cutting to an outer circumferential surface of a blank, and a tooth surface forming process for forming a tooth surface by pressing a rolling die against a roughly-processed tooth surface of the roughly-processed gear, wherein a length of a portion of the roughly-processed tooth surface, to which a plastic deformation is applied by the rolling die, in a face width direction is formed to be shorter than a length of a face width of the roughly-processed tooth surface.

Abstract: A method of determining a desired power level (P) as a function of relative tool to workpiece position, thereby enabling adaptive control advantages that were previously inaccessible for machining, such as bevel gear grinding, from solid applications. Preferably, set point power is expressed as a function of specific power (P?, P?) and roll position (Q) for a generated gear or as a function of specific power and plunge position for a non-generated (i.e. Formate) gear. Specific power is defined and preferably remains as defined during machining even as process conditions vary during machining.

Abstract: A method of assembling a planetary gearset includes die-forming a plurality of circumferentially spaced apart teeth on a sun gear, a planet gear and a ring gear. Each tooth includes a pair of tooth flanks in a final net form for engagement with mating gear teeth. The sun gear teeth have a conical shape to allow a first die to linearly move relative to a second die after the gear teeth are die-formed. The planet gears are mounted on a carrier. The sun gear and the planet gear are oriented such that the conical shapes of the respective gear teeth taper in opposite directions from one another and the planet gear teeth meshingly engage with both the ring gear teeth and the sun gear teeth.

Abstract: A novel method of manufacturing a toothed disc is taught wherein the teeth can be cold formed to a relatively high set of tolerances in a relatively time-efficient manner. A cold-formed disc blank with an annular thickened ring about its periphery is forced through a set of tooth forming rollers which engage the annular thickened ring. As the blank is forced through the set of rollers, the rollers cold forming tooth structures in the annular ring. In some circumstances, the tooth structure can be a final desired tooth profile and in other circumstances, the disc blank may be forced through two or more different sets of tooth forming rollers, each set of tooth forming rollers contributing to the forming of the final, desired tooth profile.

Abstract: The invention relates to a bevel gear wheel of a bevel gear mechanism, the teeth of which bevel gear wheel have in each case a load flank and a rear flank, wherein the rear flanks have an engagement region for rear flanks of the meshing gear wheel, wherein the outer region, which surrounds the original maximum possible usable engagement region which normally comes into engagement, of the rear flank and an outer edge region of the original engagement region are reduced in terms of the face height thereof such that said reduced regions always remain free from contact and only the remaining, inner, raised region which is reduced in size comes into contact.

Abstract: A forged composite gear and a method of making a forged composite powder metal gear. The forged composite gear includes a plurality of teeth extending from a core, a first section having a first powder metal material, a second section having a second powder metal material and a variable boundary profile. The variable boundary profile is formed between the first section and the second section, whereby said variable boundary profile exhibits greater tooth wear resistance on the teeth and greater impact resistance in the core.

Abstract: A method for producing an at least partially surface-densified metallic toothed element comprising a densified sintering material, in order to improve a strength profile, a preform of the toothed element being produced with a locally selective oversize profile relative to a final size of the toothed element and being rolled to the final size by means of at least one rolling die, the toothed element being densified in locally varied manner at least in the region of at least one flank and/or one root of a tooth of the toothed element to produce a densified outer layer.

Abstract: A method of determining an optimized face cone element for spiral bevel and hypoid gears. The form of the root fillet of one member of a gear pair is determined and that from is transferred to the tip of the other member of the gear pair. With the inventive method, tooth root-tip clearance is optimized and the contact ratio is maximized while avoiding root-tip interference between mating gear members.

Abstract: A method for producing an at least partially surface-densified metallic toothed element comprising a densified sintering material, in order to improve a strength profile, a preform of the toothed element being produced with a locally selective oversize relative to a final size of the toothed element and being rolled to the final size by means of at least one rolling die, the toothed element being densified in locally varied manner at least in the region of at least one flank and/or one root of a tooth of the toothed element to produce a densified outer layer.

Abstract: A bending state known as “coning,” in which the amount of bending of the flexspline gradually decreases in accordance with the distance from the open end of the spline, occurs in cup-type or “silk hat”-type wave gear devices. A tooth profile in which the tooth depth is kept constant and in which the bottom lands and top lands are parallel to each other along the tooth trace direction is used as the basic tooth profile for the circular spline and the flexspline of the wave gear device. A taper surface is formed on a part of the top land near the open end of the flexspline in the basic tooth profile, whereby a modified tooth profile is obtained. The modified tooth profile is employed as the tooth profile for both of the splines. Both of the splines can be caused to mesh together without generating coning-induced interference. Both of the splines can also be subjected to gear cutting by a simple process using a typical machining mechanism.

Abstract: An apparatus for extruding helical teeth in a gear blank includes a press including a die plate and a die base, the die plate being movable along an axis relative to the die base, the die base supporting the gear blank. A mandrel, aligned with the axis and moveable with the die plate along the axis, includes a surface that includes helical die teeth. A servo motor drives the mandrel in rotation about the axis to the required helix angle as the mandrel moves axially relative to the gear blank.

Abstract: A sintered gear comprises: plural tooth portion having a tooth flank and a tooth bottom land; a high density area formed over entire surface of the tooth portion, the high density area having a density of 7.6 Mg/m3 or more and formed with a depth of 1 mm or more from the surface; a low density area formed in deeper area than the high density area, the low density area having a density of 7.3 Mg/m3 or less; and an intermediate area formed between the high density area and the low density area, the intermediate area having a density gradient in which the density is gradually decreased from the high density area to the low density area.

Abstract: A bending state known as “coning,” in which the amount of bending of the flexspline gradually decreases in accordance with the distance from the open end of the spline, occurs in cup-type or “silk hat”-type wave gear devices. A tooth profile in which the tooth depth is kept constant and in which the bottom lands and top lands are parallel to each other along the tooth trace direction is used as the basic tooth profile for the circular spline and the flexspline of the wave gear device. A taper surface is formed on a part of the top land near the open end of the flexspline in the basic tooth profile, whereby a modified tooth profile is obtained. The modified tooth profile is employed as the tooth profile for both of the splines. Both of the splines can be caused to mesh together without generating coning-induced interference. Both of the splines can also be subjected to gear cutting by a simple process using a typical machining mechanism.

Abstract: A gear wheel includes multiple helical toothings, each having a different helical angle. A pressing method for molding a gear wheel involves introducing a compactable material into a chamber of a pressing tool, compacting the material, exposing the helical toothings of the gear wheel, and removing the molded body from the pressing tool. A pressing tool for pressing, as one part, a gear wheel, includes a matrix, cylindrical first and second molding tool parts which can be translated along and then rotated about a longitudinal axis, and a driver coupled to the molding tool parts or driving them. The molding tool parts can be moved towards and away from each other and the inner surface of the matrix delimits the chamber and is shaped to allow a linear axial sliding movement of the compactable material relative to the matrix.

Abstract: A transmission shift mechanism for use with a vehicle transmission. The transmission shift mechanism includes a user-operated selector and a sub-assembly operably disposed between said user-operated selector and the vehicle transmission. The sub-assembly includes a torque-transfer member having a first portion and a second portion wherein the first portion is pivotally secured to the transmission shift mechanism about a pivot axis and the second portion defines a section of a substantially spherical surface which is engageably disposed within a non-linear camming slot defined by the transmission shift section. The torque-transfer member takes the form of a molded polymeric body with a sheet metal insert disposed within the molded polymeric body. The second portion of the torque-transfer member may include flats to reduce the volume of polymeric material required in the manufacture of the member. A method of manufacturing such a torque-transfer member or crank arm is also disclosed.

Abstract: A method of manufacturing a forged article (10) including a surface (18). The method includes defining a negative tooling pattern (52) based on the surface and providing a tooling set (28) having an anvil (30) and top (36) and bottom die (34). An upper surface (40) of the bottom die conforms to the negative tooling pattern. When the tooling is assembled the anvil extends through the bottom die and defines an axis. Additionally, the bottom and top dies cooperate to define a die cavity (76). A hollow blank (38) is preheated and placed on an anvil and into the die. In a single stroke, the hollow blank is pressed between the top and bottom dies in a pressing direction that is parallel to the axis. The preheating temperature Tw is a function of the homologous temperature ratio Tw/Tm is between 0.62 and 0.80, where Tm is the absolute melting temperature of the alloy.

Abstract: A method for producing an at least partially surface-densified metallic toothed element comprising a densified sintering material, in order to improve a strength profile, a preform of the toothed element being produced with a locally selective oversize relative to a final size of the toothed element and being rolled to the final size by means of at least one rolling die, the toothed element being densified in locally varied manner at least in the region of at least one flank and/or one root of a tooth of the toothed element to produce a densified outer layer.

Abstract: A method and an apparatus are described for producing a gear wheel from a powder metal blank (1) which is sintered and pressed with an overmeasure in the flank and root region of the teeth and which in the region of the overmeasure is densified under plastic deformation by the overmeasure by pressing in a counter-toothing (3) of a pressing tool (2) which engages in the toothing (4). In order to provide advantageous conditions it is proposed that during the plastic deformation of the flank or foot region of the tooth, the tip surface of the respective tooth is subjected to a pressure force counteracting an extension of the tooth.

Abstract: A method is provided for manufacturing a compound helically toothed planet gear for a planetary gear set wherein the individual gear elements of the compound planet gear have different leads. The method identifies and utilizes the several factors affecting gear timing for compound helical planet gears having different leads to provide planet gears capable of attaining equal load share among the several gears of the planetary gear set. Specifically, the method of the present invention utilizes a mounting shoulder and bore axis to provide common locating features for use throughout the manufacturing process The method further provides for bore honing and removal of equal amounts of material from both sides of each gear tooth in the gear finishing process so as not to alter gear timing between the compound gear elements.

Abstract: A differential assembly for a motor vehicle includes a plurality of pinion gears in meshing engagement with a plurality of side gears. At least one of the pinion gears and side gears is formed from a heated tubular preform in a forging die. A method for manufacturing a differential assembly is also provided.

Abstract: Methods for manufacturing a flanged article (21) that comprises a central depressed body (27) and a peripheral flange (23) may include press forming a material (10) in order to form an intermediate flanged article (20) that comprises a central depressed body (26) and a peripheral flange (22). Then, the peripheral flange of the intermediate flanged article may be circumferentially squeezed in order to thicken the peripheral flange due to plastic flow caused by plastic deformation. The press forming step optionally may include forming a toothed portion (24) on an inner surface (22a) of the peripheral flange. The squeezing step optionally may include reshaping the toothed portion. Apparatus (1, 2) for performing each of these method steps are also described.

Abstract: In a method of making a rotation-symmetrical gear member, an outer edge of a circular blank is shaped to form a concentric thickened area which extends in axial direction to thereby realize a ring structure. A remaining area of the circular blank is then shaped into a cap-like structure through application of compressive forces by means of a pressure roller such that the ring structure adjoins a sidewall of the cap structure and projects outwardly in radial direction. The ring is then formed with outer teeth in opposition to the sidewall.

Abstract: A technique for manufacturing a gear rack (5) for a rack-and-pinion steering gear for automobiles makes use of a blank (18) for the gear rack (5) having at least in the latter's toothed area a form deviating from a circular cylinder. Size and form of the cross-section of the blank (18) are selected in a manner that the contour of the finished gear rack (5) in the toothed area (7) does not project beyond the envelope given by the dimensions of neighboring parts of the rack-and-pinion steering gear. The gear rack (5) is formed from the blank (18) by means of tumble-forging. After tumble-forging, the gear rack (5) in its toothed area (7) outside the toothed section has a convex or concave longitudinal profile, which serves to support the tumbling torques during tumble-forging.

Abstract: The invention is intended to reduce the installation cost and running cost, minimize the production cost and increase the tooth surface strength of hypoid teeth.

Abstract: A method for manufacturing profiles formed so as to have different cross-sectional shapes in the height direction, in which a long-sized hoop of workpiece is indexed, a plurality of types of component members having outer contours corresponding to the respective cross-sectional shapes of the profile are formed in a plurality of stages and indexed in the state where the component members are replaced on the workpiece, and the component members are sequentially ejected from the workpiece, laminated into a profile in the final stage.

Abstract: A process for manufacturing polymer/metal disks in a single piece batch size comprises applying a bonding agent to a metallic hub, pressing a polymeric ring over the metallic hub to form a ring/hub assembly, and heating the ring/hub assembly to cause bonding to occur between the polymeric ring and the metallic hub. The bonding agent may either be sprayed or applied directly to the metallic hub. Other methods of application may also be employed, such as dipping of the metallic hub in the bonding agent. The bonding agent is generally an organosilane, although other compounds capable of bonding a polymer to a metallic substrate can be used. The pressing of the polymeric ring over the metallic hub comprises enlarging the polymeric ring and mounting it over the metallic hub. The enlargement of the polymeric ring is typically effectuated either with heat or by stretching.