Double-Helical Gear Hobbing with Angularly Offset Gear Halves
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Solution Overview
Problem
The challenge in chipping production of gear wheels with true arrow teeth is the limited space for the chipping tool, which requires widening the gear wheel to accommodate the tool, and existing methods struggle to efficiently machine the teeth to the apex point due to the overlapping nature of the gear halves.
Innovation Solution
The method involves offsetting the gear halves by an angle relative to the axis of rotation, allowing the hobbing tool to reach into adjacent tooth gaps for complete machining without collision, utilizing a hobbing process that combines roll milling and ramming with axial advancing, enabling efficient production with reduced machining time and minimized workpiece width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gear halves are arranged with overlapping teeth (double-helical configuration), then the gear wheel achieves continuous engagement and smooth operation, but there is insufficient space for the chipping tool to machine the teeth to the apex point
Solution Approach 1:
The patent introduces an angular offset between the two gear halves around the rotation axis, creating a new spatial dimension for tool access. This angular displacement allows the chipping tool to approach the tooth apex from a different angular position, bypassing the interference caused by overlapping teeth in the radial direction.
Solution Approach 2:
The gear wheel is divided into two distinct gear halves that are angularly offset from each other. This segmentation allows each gear half to be machined independently, with the offset configuration providing clearance for the tool to access the tooth apex of one gear half without interference from the other gear half.
2Ease of operation
If a circumferential groove is formed to provide tool clearance, then the chipping tool can access the tooth apex, but the gear wheel width increases by the groove width
Solution Approach 1:
Instead of creating clearance in the axial direction (which would increase gear wheel width), the patent utilizes the angular dimension around the rotation axis. The gear halves are offset angularly, allowing the tool to access the tooth apex through the angular space created by the offset configuration, without requiring additional axial width.
Solution Approach 2:
The patent changes the spatial parameters of the gear wheel configuration by introducing an angular offset between gear halves. This parameter change repositions the teeth in the angular direction, creating clearance for tool access without modifying the axial dimensions of the gear wheel.
3Ease of manufacture
If conventional milling is used to machine the teeth, then the process is simple, but the machining time increases and productivity decreases
Solution Approach 1:
The hobbing process is a continuous cutting operation where the hobbing tool engages the gear blank continuously, removing material in a smooth, uninterrupted flow. This continuous action eliminates the intermittent cutting and repositioning required in conventional milling, significantly reducing machining time while maintaining process simplicity through standardized gear manufacturing methodology.
Solution Approach 2:
The patent replaces the conventional milling process with hobbing, which uses a different mechanical cutting mechanism. Instead of a milling cutter rotating perpendicular to the gear axis, a hobbing tool rotates parallel to the gear axis, creating continuous cutting action that is more efficient for gear tooth production.
Data Source
AI summary
The invention makes available a method for the production of gear wheels, with which it is possible to produce gear wheels having double-helical teeth, in particularly efficient manner. For this purpose, in the case of the method according to the invention for chipping production of a gear wheel, which is provided with double-helical teeth, in which the teeth of the one gear half are configured to run counter to the teeth of the other gear half, in rising manner, wherein the gear halves are arranged offset from one another by an angle amount with reference to the axis of rotation of the gear wheel, a gear wheel blank is made available, on which the teeth provided on the gear wheel are produced by means of hobbing, using a hobbing wheel, which, during hobbing machining of the teeth, in each instance, of one of the gear halves, reaches all the way into the adjacent tooth gaps of the other gear half, in each instance.