Conical Grinding Worm for Asymmetrical Gear Tooth Modifications
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Solution Overview
Problem
Current diagonal rolling methods for gear machining lack flexibility in producing modifications, particularly in achieving uniform tool wear and asymmetrical tooth flank modifications.
Innovation Solution
The use of a conical grinding worm with a conical basic shape, allowing for a diagonal ratio between the axial feed of the tool and workpiece, enables targeted modifications of the surface geometry on both flanks, utilizing a conical tool with an involute tooth system and varying the dresser position during dressing to achieve desired tooth flank modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a cylindrical grinding worm is used in diagonal generating grinding, then the tool can machine the workpiece with standard geometry, but the flexibility in producing modifications is limited and uniform tool wear cannot be achieved
Solution Approach 1:
The patent applies parameter changes by transitioning from a cylindrical tool geometry to a conical tool geometry. This fundamental parameter change in the tool's basic shape enables the diagonal generating grinding method to produce various modifications (such as crowning, lead correction, and tooth flank modifications) by adjusting the cone angle and other conical parameters, thereby achieving the desired flexibility in producing modifications while maintaining a well-defined geometric form
Solution Approach 2:
The conical basic shape of the grinding worm introduces asymmetry in the tool geometry, which allows for different modifications on the left and right tooth flanks of the workpiece. This asymmetric geometry enables independent control of modifications on each flank, providing the flexibility needed to correct asymmetrical toothings and achieve uniform wear distribution across the tool surface
2Reliability
If axial feed of the tool is increased to achieve uniform tool wear, then tool life is improved, but the ability to produce specific surface modifications is reduced
Solution Approach 1:
The patent applies dynamics by making the diagonal ratio variable rather than constant. The diagonal ratio, which is the ratio between the axial feed of the tool and the axial feed of the workpiece, can be dynamically adjusted during the grinding process. This dynamic adjustment allows the system to optimize both tool wear uniformity and surface modification precision by adapting the feed rates to the specific modification requirements and tool wear state
3Adaptability or versatility
If a conical grinding worm is used to achieve flexibility in modifications, then asymmetrical toothings can be produced, but the device complexity increases
Solution Approach 1:
The patent applies local quality by enabling different modifications on the left and right tooth flanks of the workpiece through the conical tool geometry. The cone angle and other conical parameters can be locally adjusted to produce specific modifications (such as different crowning, lead correction, or tooth flank modifications) on each flank independently, allowing precise control over the local geometry of asymmetrical toothings
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 enhances flexibility in producing workpieces with corrected toothing geometry and modified surface structures, allowing for different modifications on the left and right tooth flanks, reducing machining time, and enabling the production of asymmetrical toothings with precise control over modifications.
Implementation Method 1
these are generating grinding processes in which a workpiece is hard-fine machined by rolling a grinding worm
Data Source
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Figure 3a~3b
AI summary
The present invention shows a method for gear-machining a workpiece by a diagonal generating method, in which the workpiece is gear-machined by rolling a tool, with an axial feed of the tool taking place during machining with a diagonal ratio given by the ratio between the axial feed of the tool and the axial feed of the workpiece . The tool has a conical basic shape.