Bevel Gear Slide Rolling With Reduced Roll Angle Cutting
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Solution Overview
Problem
In the production of straight bevel gears, the use of single rotary disc cutters leads to high part temperature, poor cutting performance, and low tool life due to severe chip removing loads on the blade tips, primarily because of the necessity to cut on both sides of the blades, including the clearance side, which is not optimally suited for chip removal.
Innovation Solution
The method involves reducing the workpiece roll angle during the generating process to minimize or eliminate cutting action on the clearance side of the rotary disc cutter, allowing the cutting action to focus on the sharp edge, thereby reducing chip load on the dull clearance side and extending tool life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single rotary disc cutter is used to cut both sides of the blade, then the device complexity is reduced, but the tool life decreases due to severe chip removing loads on the blade tips
Solution Approach 1:
The invention divides the cutting process into two distinct phases: a plunging phase for slot formation and a generating roll phase for tooth flank generation. This segmentation allows each phase to use optimized cutting parameters and motions, reducing the severe chip removing loads that previously occurred when a single cutter attempted to perform both functions simultaneously.
Solution Approach 2:
The invention introduces dynamic motion control by implementing a generating roll motion where the workpiece and cutter rotate relative to each other with a specific roll angle. This dynamic motion transforms the static severe loading condition into a controlled generating process that reduces chip load on blade tips, thereby extending tool life while maintaining the single cutter configuration.
2Productivity
If the cutter cuts on both sides including the clearance side, then the productivity is maintained, but the part temperature increases due to poor cutting performance
Solution Approach 1:
The invention performs preliminary action by using the plunging motion to create the tooth slot and remove the bulk of material before the generating roll phase begins. This preliminary material removal reduces the subsequent chip load during the generating phase, improving cutting performance and reducing part temperature while maintaining overall productivity.
Solution Approach 2:
The generating roll motion creates a periodic cutting action where the cutter and workpiece rotate in a coordinated manner. This periodic motion allows for controlled chip removal with reduced contact time and lower temperatures compared to continuous severe cutting, while still achieving the required material removal for tooth flank generation.
3Manufacturing precision
If the clearance side of the blade is used for cutting, then the manufacturing precision is maintained, but the tool life decreases due to severe chip removing loads
Solution Approach 1:
The invention applies local quality by using different cutting modes for different parts of the blade. The sharp cutting edge is used for the plunging phase where heavy material removal is needed, while the generating roll phase uses a reduced roll angle to minimize clearance side contact. This localized optimization allows the clearance side to participate in cutting only when necessary for precision, while protecting the blade tips from severe loads.
Solution Approach 2:
The invention changes the roll angle parameter during the generating process to optimize the balance between manufacturing precision and tool life. By reducing the roll angle, the clearance side cutting action is minimized, reducing chip load on blade tips and extending tool life while still achieving the required tooth flank accuracy through the controlled generating motion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the occurrence of clearance side cutting, leading to lower part temperatures, improved cutting performance, and increased tool life by ensuring that only the sharp cutting edges handle the majority of the chip removal, thus enhancing the overall efficiency of the gear-cutting process.
Implementation Method 1
a generating process for producing bevel gears and employing a single rotary disc cutter wherein a portion of the generating cutting process effectively includes a reduction of the workpiece roll angle during generating thereby reducing or eliminating cutting action on the clearance side of the rotary disc cutter
Data Source
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AI summary
Generating cutting processes for producing bevel gears and employing a single rotary disc cutter (36) wherein a portion of the generating cutting process effectively includes a reduction (38) of the workpiece roll angle (40) during generating thereby reducing or eliminating cutting action on the clearance side (42) of the rotary disc cutter.