Two-Stage Chamfering for Bevel Gear Burr Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for chamfering bevel gears often result in secondary burrs, which pose risks of injury, contamination, and tool damage, and are difficult to remove efficiently, especially in series production.
Innovation Solution
A two-stage method using a programmable CNC-controlled bevel gear cutting machine with additional axes allows for precise control of deburring tools to create a double facet with a steep inclination, reducing material removal and avoiding tertiary burrs, and is implemented in a continuous process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If deburring tools are used to remove primary burrs, then tooth edges are chamfered, but secondary burrs occur when cutting edges become blunt
Solution Approach 1:
The deburring operation is segmented into two passes with different tool orientation angles. The first pass uses a larger angle (30-60 degrees) for primary burr removal, while the second pass uses a smaller angle (10-30 degrees) for secondary burr removal. This segmentation ensures that each pass operates within optimal cutting parameters, maintaining reliability even as tools wear.
Solution Approach 2:
The cutting parameters are changed between passes: the first chamfering uses specific depth and angle parameters to remove primary burrs, while the second chamfering uses different parameters (smaller angle, controlled depth) to remove secondary burrs without creating new ones. This parameter optimization maintains consistent results throughout tool life.
2Object-generated harmful factors
If nylon or brass brushes are used to remove secondary burrs, then burrs can be removed, but the tools are subject to wear and require replacement
Solution Approach 1:
The mechanical brush-based removal system is replaced with a controlled chamfering cutting system. Instead of using abrasive brushes that wear quickly, the invention uses precision cutting tools with defined geometry to mechanically remove secondary burrs through controlled chip formation. This substitution dramatically extends tool life and maintains consistent removal effectiveness.
3Object-generated harmful factors
If a two-stage chamfering method is implemented, then secondary burrs are reliably removed, but processing time increases
Solution Approach 1:
The two-stage chamfering process is implemented as a continuous operation where the workpiece and tool rotate and move in a coordinated manner without interruption. Both chamfering passes are performed in one continuous machining cycle, eliminating the need for separate operations or tool changes, thus minimizing the time penalty of the two-pass approach.
Data Source
Figure 1A~1B
Figure 1C~2
Figure 3
AI summary
bevel gear cutting machine (200) with several numerically controllable axes, wherein the cutting machine (200) has a workpiece spindle (205) which accommodates a bevel gear (10) coaxially to a workpiece spindle axis (B) and a deburring device (50) with deburring spindle (51) for accommodating at least one first deburring tool (60). The bevel gear cutting machine (200) is designed for chamfering the tooth edges of the bevel gear (10) in two passes, wherein - in a first pass, first chamfers are provided on the tooth edges by using the first deburring tool (60) in a continuous process, and - in a second pass, second chamfers are provided in the area of the first chamfers by using the first deburring tool (60), or by using a second deburring tool in a continuous process in which the bevel gear (10) and the first or second deburring tool (60) rotate in coupled engagement with each other.