Diagonal Gear Cutting with Variable Ratio for Surface Control
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Solution Overview
Problem
Existing gear machining methods using diagonal rolling techniques lack flexibility in modifying gear geometry and inefficiently utilize grinding tool areas, leading to suboptimal wear distribution and surface modifications.
Innovation Solution
The method involves dynamically varying the diagonal ratio during machining, allowing for targeted modifications of the workpiece surface geometry by adjusting the axial feed of both the tool and workpiece, using a grinding worm, and employing different diagonal ratios for various tool areas to achieve desired surface features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a constant diagonal ratio is used during machining, then the machining process is simple to control, but the flexibility in modifying gear geometry is limited and tool wear is not optimized
Solution Approach 1:
The patent applies the dynamics principle by transitioning from a static, constant diagonal ratio to a dynamic, variable diagonal ratio that changes during the machining process. The control system adjusts the diagonal ratio in real-time based on the axial positions of the tool and workpiece, enabling flexible modification of gear geometry while maintaining coordinated control through the relationship between axial feeds and rotational movements.
Solution Approach 2:
The patent implements parameter changes by varying the diagonal ratio as a function of axial feed positions. The control system modifies the diagonal ratio parameter dynamically during machining, allowing different sections of the gear to be machined with different diagonal ratios, thereby achieving diverse geometric modifications and optimized tool wear patterns.
2Productivity
If the entire tool surface is used for machining, then productivity increases, but tool wear becomes uneven and tool life decreases
Solution Approach 1:
The patent applies local quality by creating a correspondence between different axial positions of the tool and workpiece and different diagonal ratios. This ensures that specific areas of the tool surface are systematically engaged with specific areas of the workpiece, distributing wear more evenly across the tool surface while maintaining high productivity through continuous machining.
3Manufacturing precision
If the diagonal ratio is varied during machining, then surface modification precision improves, but the control system complexity increases
Solution Approach 1:
The patent implements feedback control by continuously monitoring the axial positions of the tool and workpiece and using this information to adjust the diagonal ratio in real-time. The control system receives position feedback and automatically modifies the diagonal ratio to achieve the desired surface modifications with high precision.
Solution Approach 2:
The control system acts as an intermediary that coordinates the relationship between axial feeds, rotational movements, and diagonal ratio variations. It translates the interaction between tool and workpiece axial movements into appropriate diagonal ratio adjustments, enabling precise surface modifications without requiring direct complex mechanical linkages.
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 the flexibility of gear machining, optimizes tool wear, and allows for precise control over surface modifications, improving the quality and efficiency of gear production.
Implementation Method 1
a grinding worm is preferably used as the tool
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The present invention discloses a method for gear machining of a workpiece by a diagonal rolling process, in which the workpiece is gear-machined by rolling a tool, wherein during machining an axial feed of the tool is carried out with a diagonal ratio determined by the ratio between the axial feed of the tool and the axial feed of the workpiece. The diagonal ratio is varied during the machining of the workpiece.