Combination Tool Chamfer Skiving and Filing for Burr-Free Gears
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Solution Overview
Problem
The existing methods for machining toothed workpieces, such as gears, often result in burrs that require additional processing steps for removal, increasing manufacturing complexity and inefficiency due to the need for separate tools and clamping operations.
Innovation Solution
A method and device utilizing a combination tool with both a skiving and filing section, allowing for simultaneous chamfering and deburring in a single clamping operation, where the tool's machining sections are oriented to efficiently remove burrs without re-clamping the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate filing tool and machine are used to remove burrs after chamfering, then burr removal is achieved, but manufacturing complexity and time increase due to additional tools, machines, and re-clamping operations
Solution Approach 1:
The patent combines two separate machining operations (chamfering and filing) into a single tool called a combination tool. The tool has a first machining section for chamfering and a second machining section for filing, both integrated on one tool body. This merging eliminates the need for separate tools and machines, directly reducing device complexity while maintaining burr removal quality.
Solution Approach 2:
The combination tool is designed with multi-functionality to perform both chamfering and filing operations. The tool can machine the chamfer and remove burrs in sequence during a single clamping operation, making one tool serve multiple purposes that previously required separate specialized tools and processes.
2Manufacturing precision
If separate clamping operations are performed for chamfering and filing, then each operation can be optimized, but production time increases due to repeated clamping and repositioning
Solution Approach 1:
The patent enables continuous machining action by performing both chamfering and filing operations in one clamping without interruption. The workpiece remains clamped throughout the entire process, and the combination tool sequentially executes both machining tasks, eliminating idle time for re-clamping and repositioning operations.
Solution Approach 2:
The combination tool is designed beforehand to include both the chamfering section and filing section in a specific arrangement. This preliminary design of the tool structure allows it to automatically perform both operations in the correct sequence during a single clamping, eliminating the need for separate setup and clamping operations.
3Manufacturing precision
If multiple separate tools are used for chamfering and filing, then each tool can be specialized, but tooling cost and machine outlay increase
Solution Approach 1:
The patent merges the functionality of multiple specialized tools into a single combination tool. By integrating the chamfering section and filing section on one tool body, the invention reduces tooling costs and machine outlay while maintaining the specialized machining capabilities needed for high-quality chamfer and filing operations.
Solution Approach 2:
The combination tool achieves universality by incorporating multiple machining functions in one tool. This multi-functional design reduces the total number of tools and machines required, lowering overall manufacturing costs while preserving the precision and quality associated with specialized machining operations.
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
A method for machining a toothed workpiece (1), wherein the method comprises a step 1) of producing a chamfer on the toothed workpiece (1) by skiving, wherein a tool (2) rotating about a tool axis (WZA) slides with a toothed first machining portion (6) over the workpiece (1), rotating about a workpiece axis (WSA), in a contact zone (KZ), wherein the workpiece axis (WSA) defines an x direction, and the perpendicular of the contact zone (KZ) to the workpiece axis (WSA) defines a z direction, and the x direction, a y direction and the z direction form a Cartesian coordinate system, and wherein the tool axis (WZA) has been pivoted through an azimuth angle φ1≠0° with respect to the x direction, and the tool axis (WZA) has also been pivoted through a polar angle Θ1 <90° with respect to the z direction, is characterized in that the tool (2) is selected to be a combination tool, which, in addition to the toothed, first machining portion (6), also has a second machining portion (9), wherein the second machining portion (9) extends, with regard to a cutting plane (SE) that contains the tool axis (WZA), at a filing edge angle α > 0° with respect to the first machining portion (6), in that the method also comprises a step 2) of filing an end side (8) of the toothed workpiece (1), said end side (8) adjoining the chamfer produced in step 1), wherein the rotating tool (2) slides with the second machining portion (9) over the workpiece (1), rotating about the workpiece axis (WSA), in a file contact zone (FZ), and in that steps 1) and 2) take place in the same setup of the workpiece (1). With the invention, a chamfered and deburred workpiece can be provided quickly and easily.