A diamond tool for dressing internal meshing honing grinding wheel and its use method

Abstract

The present invention proposes a diamond tool for dressing an internal meshing honing wheel, the diamond tool comprising an annular tool base and a diamond layer disposed on the front side of the tool base; the diamond layer is coaxially fixed to the tool base; and a trimming bevel tooth is provided on the outer periphery of the diamond layer so that the end face tooth edges of the trimming bevel tooth are used to dress the honing wheel. The diamond tool of the present invention is an external tooth helical gear structure. When meshing and dressing the honing wheel, material is removed from the honing wheel only by relying on the end face tooth edges of the trimming bevel tooth on the diamond layer. The trimming bevel tooth has a trimming tooth profile, which can achieve tooth profile modification of the honing wheel. At the same time, the movement of the honing machine tool drives the diamond tool to achieve tooth direction modification of the honing wheel tooth surface. Since the tooth surface of the trimming bevel tooth does not contact the tooth surface of the honing wheel, it is suitable for dressing honing wheels with different tooth direction modification requirements.

Description

Technical Field

[0001] The present invention relates to the technical field of grinding, in particular to a diamond tool. Background Art

[0002] Gears are key basic components in industry and are used in almost every field of the national economy. The internal meshing high-power honing process is a typical hard tooth surface finishing process method, which uses a honing wheel with an internal helical tooth shape to grind the tooth profile and tooth direction of the gear workpiece. The honing process can form an arc-shaped tooth surface texture on the workpiece tooth surface that is inclined along the tooth top and tooth root direction, eliminating the high-frequency noise source generated by the regular texture of tooth grinding and improving the surface load factor. With the increasing demand for gear precision in modern industry, the honing process has gradually replaced gear grinding as the final process to improve the meshing characteristics and noise of gears.

[0003] During the honing process, the abrasive on the honing wheel's surface inevitably wears due to the grinding forces and temperatures. This leads to a loss of tooth profile accuracy, a reduction in the profile accuracy and surface quality of the gear workpiece, and causes vibration, noise, and other phenomena. Therefore, the honing wheel needs to be dressed. Currently, honing wheels used for internal gear honing typically use an electroplated diamond dressing wheel with the exact same shape as the workpiece gear. This wheel replaces the workpiece and is placed in the workpiece position on the power honing machine. The meshing motion between the two allows for the honing wheel to be dressed.

[0004] However, this dressing method requires a one-to-one correspondence between dressing wheels and gear workpieces. This means that each dressing wheel can only be used to produce a honing wheel that meets one required shaping requirement. This limits the applicability of each dressing wheel and reduces its practicality. Furthermore, the manufacturing process for electroplated rollers is complex and time-consuming. To produce honing wheels for different shaping requirements, multiple different dressing wheels must be manufactured, resulting in high costs.

[0005] A utility model patent, published on July 10, 2013, and numbered CN203045529U, discloses a worm grinding wheel dressing tool. The tool comprises two diamond grinding wheels, each with its working bevel facing each other and a spacer positioned between them. The wheels are secured to a grinding machine shaft. This utility model patent aims to provide a worm grinding wheel dressing tool. This tool, utilizing two diamond grinding wheels and a spacer, is capable of grinding various gears and meeting the requirements for tooth top trimming according to the designed tooth profile. However, the patent cannot be used for honing grinding wheels.

[0006] The invention patent, published on May 31, 2024, and with publication number CN118106886A, discloses a desktop grinding wheel dresser, comprising an adaptive dressing structure and a cooling structure. The cooling structure comprises a cooling water channel arranged in the axial direction of the diamond dressing pen holder. The adaptive dressing structure comprises a spring-loaded piston rod at the bottom of the diamond dressing pen, a dressing pen holder with bearings at both ends at the bottom of the diamond dressing pen, and a pull rod on the side of the grinding wheel dresser that cooperates with the piston rod and the dressing pen holder. No additional cooling device is required, and the cooling water sprayed along the axial direction of the tool has a good cooling effect, effectively extending the tool's practical life. When dressing special-shaped grinding wheels, the diamond pen can adapt to the grinding wheel shape, maintaining a certain angle with the grinding wheel's outer contour, thereby improving the grinding wheel dressing efficiency. However, the above patent cannot be used for reshaping honing wheels.

[0007] An invention application, published on July 23, 2024, and with publication number CN118371794A, discloses a dresser structure and parameter design method for dressing honing wheels. The method includes the following steps: Step 1: Determine the dressing wheel measuring rod span M2 based on the parameters of the gear being processed; Step 2: Calculate the dressing wheel tooth tip diameter da2; Step 3: Calculate the dressing wheel tooth root diameter dg2; Step 4: Calculate the dressing wheel effective tooth root diameter dnf2; Step 5: Calculate the dressing wheel effective tooth tip diameter dna2; and Step 6: Design a dressing wheel for the dresser structure used for dressing honing wheels based on the parameters obtained in Steps 1, 2, 3, 4, and 5. However, the dressing wheel calculated in this application cannot be used to shape honing wheels with different shaping requirements. Summary of the Invention

[0008] To address the aforementioned technical issues, the present invention proposes a diamond tool for dressing internally meshing honing wheels. This tool addresses the existing problem of a single dressing tool only being able to handle a single honing wheel profile. This tool can be used to dress honing wheels with multiple profiles, offering high flexibility and a short manufacturing cycle, improving the practicality of a single dressing tool and reducing costs.

[0009] In order to achieve the above object, the technical solution of the present invention is achieved as follows:

[0010] A diamond tool for trimming an internal meshing honing wheel comprises an annular tool base and a diamond layer disposed on the front side of the tool base; the diamond layer is coaxially fixed to the tool base; and trimming bevel teeth are provided on the outer periphery of the diamond layer so that the end face tooth edges of the trimming bevel teeth can be used to trim the honing wheel. The diamond tool of the present invention is an externally toothed bevel gear structure. When performing meshing trimming on the honing wheel, material is removed from the honing wheel only by relying on the end face tooth edges of the trimming bevel teeth on the diamond layer. The trimming bevel teeth have a trimming tooth profile, which can achieve tooth profile trimming of the honing wheel. At the same time, the movement of the honing machine tool drives the diamond tool to achieve tooth direction trimming of the honing wheel tooth surface. Since the tooth surface of the trimming bevel teeth does not contact the tooth surface of the honing wheel, it is suitable for trimming honing wheels with different tooth direction trimming requirements.

[0011] Furthermore, in order to form a more suitable end face tooth edge between the tooth surface of the modified helical tooth and the front end face of the modified helical tooth, the back angle of the diamond tool is 5 to 10 degrees.

[0012] Furthermore, in order to make the end face tooth edge of the modified helical tooth sharper and improve the dressing effect, the front angle of the diamond tool is 5 to 10 degrees.

[0013] Furthermore, in order to provide a better support for the modified bevel teeth on the diamond layer, base bevel teeth are provided on the periphery of the tool base.

[0014] Furthermore, in order to better support the modified bevel teeth on the diamond layer, the base bevel teeth correspond to the modified bevel teeth one by one, and the rear end face of the base bevel teeth is fixed to the front end face of the modified bevel teeth.

[0015] Furthermore, in order to avoid interference of the basic helical teeth on the shaping process of the modified helical teeth, the longitudinal section size of the basic helical teeth is an equidistant reduction of the modified helical teeth.

[0016] Furthermore, in order to provide a better support for the modified bevel teeth on the diamond layer, the tooth thickness of the base bevel teeth is equal to the tooth thickness of the modified bevel teeth.

[0017] Furthermore, in order to ensure the cutting angle of the modified helical teeth on the diamond tool while avoiding interference, the tooth thickness of the modified helical teeth is smaller than the tooth thickness of the gear workpiece processed by the corresponding honing wheel, and the helix angle of the modified helical teeth is smaller than the helix angle of the gear workpiece.

[0018] Furthermore, in order to ensure reliable and stable fixation of the diamond layer to the tool base, the diamond layer is fixed to the front end surface of the tool base by brazing.

[0019] The preparation method of the diamond tool for dressing the internal meshing honing wheel as described in any of the above items includes clamping the diamond tool at the workpiece position of the honing machine tool, and the diamond tool is installed at an axial intersection angle γ with the honing wheel to be dressed, and the tooth profile of the honing wheel is modified by the spatial meshing movement of the diamond tool and the honing wheel; at the same time, the gear honing machine tool is used to control the diamond tool to move along the tooth direction of the honing wheel to achieve tooth direction modification of the honing wheel.

[0020] Beneficial effects of the present invention:

[0021] 1. The diamond tool of the present invention has an external tooth helical gear structure. When the honing wheel is meshed and trimmed, the material of the honing wheel is removed only by relying on the end face tooth profile of the diamond layer. The end face tooth profile has a trimming tooth profile, which can realize the tooth profile trimming of the honing wheel.

[0022] 2. The tooth surface of the diamond tool of the present invention does not contact the tooth surface of the honing wheel. The tooth profile of the honing wheel tooth surface is modified by combining with the movement of the machine tool. Therefore, it is suitable for the dressing of honing wheels with different tooth profile modification requirements.

[0023] 3. The present invention provides a gear-shaped diamond tool and sets the back angle of the gear to a relatively small acute angle. The honing wheel is modified only by the tooth edge between the tooth surface and the front end surface of the tooth to form a cutting edge. This makes the tooth surface non-contact with the tooth surface of the honing wheel. Therefore, the present invention is applicable to the dressing of honing wheels with various tooth profile modification requirements.

[0024] 4. When manufacturing the diamond tool of the present invention, only the end face tooth profile needs to be processed, and there is no need to perform tooth profile modification on the tooth surface of the diamond layer. The manufacturing accuracy is easier to ensure, and the disadvantage of the traditional dressing wheel requiring precise processing of the end face tooth profile and tooth surface tooth direction, which is difficult to manufacture, is avoided;

[0025] 5. The diamond tool of the present invention does not have a one-to-one correspondence with the honing wheel to be dressed, thus getting rid of the disadvantage of the traditional one-to-one correspondence between the electroplated diamond dressing wheel and the honing wheel, reducing the manufacturing difficulty of the dressing tool and the cost of the gear honing process, and improving the processing efficiency and precision;

[0026] 6. The tooth surface of the diamond tool of the present invention has no contact with the tooth surface of the honing wheel, thus avoiding the problem of the diamond tool threshing and damaging the honing wheel surface. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0028] Figure 1 It is a structural schematic diagram of the present invention.

[0029] Figure 2 Schematic diagram of the structure of the diamond layer of the present invention.

[0030] Figure 3 It is a structural schematic diagram of the tool base of the present invention.

[0031] Figure 4 It is a schematic diagram of a partially enlarged structure of the present invention.

[0032] Figure 5 Schematic diagram of the trimming process of the present invention.

[0033] Reference numerals in the figures:

[0034] 100. Diamond layer, 101. Modified bevel tooth, 1011. End tooth edge, 1012. Tooth surface, 102. Front end face of tooth, 103. Rear end face of diamond layer, 104. Inner hole of diamond layer, 200. Tool base, 201. Front end face of base, 202. Inner hole of base, 203. Base bevel tooth, 300. Honing wheel. DETAILED DESCRIPTION

[0035] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without creative work are within the scope of protection of the present invention.

[0036] like Figures 1 to 5 As shown, the diamond tool for dressing an internal meshing honing wheel according to embodiment 1 of the present invention is a gear-shaped diamond tool, which includes an annular tool base 200 and a diamond layer 100 arranged on the front side of the tool base 20. Figure 3 As shown, the tool base 200 is a cylindrical helical external gear structure. The tool base 200 is made of metal material. Figure 2As shown, the diamond layer 100 of the diamond tool also has a cylindrical helical external gear structure, and the diamond layer 100 is coaxially fixed to the tool base 200. The outer periphery of the diamond layer 100 is provided with modified helical teeth 101, each having a modified tooth profile. End face teeth 1011 are formed between the tooth surface 1012 of the modified helical teeth 101 and the tooth front end face 102, serving as a cutting edge for dressing the honing wheel 300 to be dressed. When the diamond tool is working, it is clamped on the honing machine to engage and dress the honing wheel. The diamond tool only relies on the end tooth edge 1011 to remove material from the honing wheel, so as to achieve the tooth profile modification of the honing wheel. At the same time, the movement of the honing machine drives the diamond tool to move in the tooth direction relative to the honing wheel, so as to achieve the tooth direction modification of the tooth surface of the honing wheel. Since the tooth surface 1012 of the modified helical tooth 101 has no contact with the tooth surface of the honing wheel during the dressing process, it is suitable for the dressing of honing wheels with different tooth direction modification requirements.

[0037] In Example 2, the back angle of the diamond tool, i.e., the gear-shaped diamond tool, is 5 to 10 degrees, that is, the inclination angle of the modified helical tooth 101 relative to the axial direction of the gear-shaped diamond tool is 5 to 10 degrees, so that the end face tooth edge 1011 of the modified helical tooth 101 can better dress the honing wheel 300.

[0038] It is the same as Example 1.

[0039] In Example 3, the diamond tool, or gear-shaped diamond tool, has a rake angle of 5 to 10 degrees, meaning the front end face of the diamond layer is not perpendicular to the axis of the gear-shaped diamond tool. Specifically, in an axial cross-section of the gear-shaped diamond tool, the straight edge on the front end face forms an angle of 5 to 10 degrees with the diameter of the diamond tool, thereby sharpening the end face tooth edges 1011 of the modified helical teeth 101.

[0040] It is the same as Example 1.

[0041] Example 4, as Figure 1 and Figure 3 As shown, the outer periphery of the tool base 200 is provided with base bevel teeth 203. The base bevel teeth 203 correspond to the modified bevel teeth 101 one-to-one, that is, the number of the base bevel teeth 203 and the modified bevel teeth 101 is the same, and the rear end surface of the base bevel teeth 203 is fixedly attached to the front end surface of the modified bevel teeth 101.

[0042] Furthermore, the tooth thickness of the base helical teeth 203 is equal to the tooth thickness of the modified helical teeth 101 .

[0043] In addition, if Figure 3As shown, only the outer circumference of the tool base 200 near the diamond layer 100 is provided with base bevel teeth 203. The outer circumference away from the diamond layer 100 is not provided with base bevel teeth 203, and this outer circumference without base bevel teeth 203 is smooth. The total thickness of the tool base 200 is twice the thickness of the base bevel teeth 203. Assuming that the tooth thickness of the base bevel teeth 203 and the tooth thickness of the modified bevel teeth 101 are both B, the total thickness of the tool base 200 is 2B.

[0044] It is the same as Example 1.

[0045] Example 5, as Figure 4 As shown, the longitudinal section size of the base helical teeth 203 is an equidistant reduction of the modified helical teeth 101 , so as to avoid interference between the tool base 200 and the honing wheel 300 to be dressed.

[0046] It is the same as Example 1.

[0047] In Example 6, the tooth thickness of the modified helical teeth 101 is less than the tooth thickness of the gear workpiece being processed by the corresponding honing wheel 300. Furthermore, the tooth thickness of the modified helical teeth 101 is less than half the thickness of the gear workpiece. Assuming the tooth thickness of the gear workpiece being processed by the honing wheel 300 to be trimmed is b, the tooth thickness of the modified helical teeth 101 is B ≤ b / 2.

[0048] Furthermore, the helix angle of the modified helical teeth 101 is smaller than the helix angle of the gear workpiece, which can further avoid interference during the trimming process.

[0049] In addition, the number of teeth, module, pressure angle and other basic gear parameters of the diamond layer 100 of the cylindrical helical external gear structure are the same as those of the gear workpiece being processed.

[0050] It is the same as Example 1.

[0051] In Example 7, a coaxial base inner hole 202 is provided in the middle of the tool base 200 . A coaxial diamond layer inner hole 104 is provided in the diamond layer 100 , and the diameter of the diamond layer inner hole 104 is slightly larger than the base inner hole 202 .

[0052] It is the same as Example 1.

[0053] Example 8, taking a certain diamond tool for dressing a honing wheel as an example, the parameters of the gear workpiece processed by the honing wheel are: normal module 3.26, pressure angle 19.5°, number of teeth 36, pitch circle helix angle 27.488°, pitch circle diameter 132.295mm, base circle diameter 122.868mm, and tooth width 55mm.

[0054] In this embodiment, the modified helical teeth 101 of the diamond tool have a modified tooth profile that matches the tooth profile of the gear workpiece. The diamond layer tooth thickness B is narrower than the gear workpiece tooth thickness b, with B being 15 mm. To ensure the tool's cutting angle and avoid interference, the diamond layer's helix angle β is generally smaller than that of the gear, with β being 10°. Other basic gear parameters, such as the number of teeth, module, and pressure angle, are identical to those of the gear workpiece being machined. The diameter of the diamond layer's inner hole 104 is slightly larger than that of the base inner hole 202, at 75.5 mm.

[0055] The tool base 200 of the diamond tool has a structure as follows: Figure 3 As shown, the inner hole 202 of the base is the reference surface for tool installation. The single tooth structure of the base bevel teeth 203 of the tool base 200 is the equidistant reduction of the modified bevel teeth 101 of the diamond layer by 0.5 mm. Figure 4 The number of teeth, tooth thickness and other parameters of the base bevel teeth 203 on the tool base 200 are the same as those of the modified bevel teeth 101 of the diamond layer. The total thickness of the tool base 200 is 30 mm, and the diameter of the base inner hole 202 is 75 mm.

[0056] The rest is the same as Example 1.

[0057] Example 9, the preparation process of the diamond tool is as follows:

[0058] S1: First, a disc-shaped polycrystalline diamond blank is prepared using a well-known high-temperature and high-pressure method, and laser cutting technology is used to control the laser to be perpendicular to the end face of the diamond blank for rough cutting, cutting the diamond blank into straight teeth.

[0059] S2: The base material is made of metal material, including but not limited to 45 steel, 40Cr, 42CrMo, etc.; in this embodiment, the base material is 40Cr and the base tooth structure is processed by a five-axis machining center, and the inner hole and end face of the base are ground.

[0060] S3: The rear end face 103 of the diamond layer is fixedly connected to the front end face 201 of the substrate by brazing, and the phase of each tooth is aligned.

[0061] S4: The welded diamond tool is positioned through the inner hole 202 of the base, and installed on the workpiece core shaft of the five-axis laser processing equipment. The laser is controlled to process along the tooth surface of the diamond layer to form a spiral helical tooth structure and realize the shaping of the diamond layer tooth shape.

[0062] The rest is the same as Example 1.

[0063] Example 10: The method for using the diamond tool is as follows:

[0064] The diamond tool is positioned through the inner hole 202 of the base, clamped in the workpiece position of the powerful gear honing machine, and installed at a certain axis angle γ with the honing wheel to be trimmed, such as Figure 5 As shown in the figure, the diamond tool and the honing wheel are spatially meshed to modify the honing wheel's tooth profile. Simultaneously, the machine tool controls the tool's movement along the tooth direction to modify the honing wheel's tooth profile. Using this tool to dress the honing wheel is highly efficient and precise, and the dressed honing wheel can meet the honing processing requirements of gear workpieces.

[0065] The rest is the same as Example 1.

[0066] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that any modification to the technical solutions described in the aforementioned embodiments, or any equivalent replacement of some or all of the technical features thereof, within the spirit and principles of the present invention, does not deviate the essence of the corresponding technical solutions from the scope of the technical solutions of the embodiments of the present invention, and should all be included in the scope of protection of the present invention.

Claims

1. A diamond tool for dressing an internal meshing honing wheel, characterized in that: The invention comprises an annular tool base (200) and a diamond layer (100) arranged on the front side of the tool base (20); the diamond layer (100) is fixed on the front end face (201) of the tool base (200) by brazing; the diamond layer (100) and the tool base (200) are coaxially fixed; and a modified bevel tooth (101) is provided on the outer periphery of the diamond layer (100) so that the end face tooth edge (1011) of the modified bevel tooth (101) is used for dressing the honing wheel (300). The back angle of the diamond tool is 5 to 10 degrees; the front angle of the diamond tool is 5 to 10 degrees; the tooth thickness of the modified helical tooth (101) is smaller than the tooth thickness of the gear workpiece processed by the honing wheel (300) to be trimmed, and the helix angle of the modified helical tooth (101) is smaller than the helix angle of the gear workpiece; the diamond tool removes material from the honing wheel only by the end tooth edge (1011); the tooth surface (1012) of the modified helical tooth (101) has no contact with the tooth surface of the honing wheel.

2. The diamond tool for dressing an internal meshing honing wheel according to claim 1, characterized in that: The outer periphery of the tool base (200) is provided with base helical teeth (203).

3. The diamond tool for dressing an internal meshing honing wheel according to claim 2, characterized in that: The base bevel teeth (203) correspond to the modified bevel teeth (101) one-to-one, and the rear end surface of the base bevel teeth (203) is fitted and fixed to the front end surface of the modified bevel teeth (101).

4. The diamond tool for dressing an internal meshing honing wheel according to claim 2 or 3, characterized in that: The longitudinal cross-sectional dimensions of the base helical teeth (203) are equal distance reductions of the modified helical teeth (101).

5. The diamond tool for dressing an internal meshing honing wheel according to claim 4, characterized in that: The tooth thickness of the base helical teeth (203) is equal to the tooth thickness of the modified helical teeth (101).

6. The method for using a diamond tool for dressing an internal meshing honing wheel according to any one of claims 1 to 5, characterized in that: The method comprises the following steps: clamping a diamond tool at a workpiece position of a gear honing machine, and installing the diamond tool at an axis intersection angle γ with a honing grinding wheel (300) to be trimmed; and achieving tooth profile trimming of the honing grinding wheel through spatial meshing movement of the diamond tool and the honing grinding wheel; and simultaneously controlling the movement of the gear honing machine to control the diamond tool to move along the tooth direction of the honing grinding wheel, thereby achieving tooth profile trimming of the honing grinding wheel.

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