Full Profile Dressing Roll for Multi-Start Grinding Worms
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Solution Overview
Problem
Existing full profile dressing rolls for cylindrical grinding worms used in small-module gear grinding face challenges such as premature wear and grain break-out in high-stress regions, leading to reduced tool life and inhomogeneous surface quality, particularly when dressing multi-start grinding worms.
Innovation Solution
A full profile dressing roll with precision-profiled, multi-ribbed synthetic diamond or hard material segments embedded in the outer envelope surface, where the segments are set back by 10-40% in the flank regions to avoid contact with the grinding worm flanks, ensuring homogeneous surface dressing and extended tool life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hard material grains are coated on the outer envelope surface of the dressing roll to enclose the grinding worm thread profile, then high accuracy and short dressing times are achieved, but the hard material grains at the tip and root of the groove profile are subjected to higher loading and greater wear
Solution Approach 1:
The patent applies different structural configurations to different regions of the dressing roll groove profile. The groove flanks maintain a standard configuration for efficient dressing, while the groove tip region is specifically modified with reinforced hard material grain anchoring structures. This local differentiation allows the high-stress tip region to retain grains more effectively without compromising the overall dressing performance of the tool.
2Manufacturing precision
If hard material grains are coated on the outer envelope surface to enclose the grinding worm thread profile, then high accuracy dressing is achieved, but the service life of the dressing tool ends prematurely due to grain break-out in high-stress regions
Solution Approach 1:
The patent implements local reinforcement of hard material grain anchoring specifically in the groove tip regions where stress concentration occurs during dressing operations. The groove flanks maintain their original design for precision dressing, while the tip zones feature enhanced grain retention through modified bonding structures or geometric configurations that prevent premature grain break-out under high loading conditions.
3Reliability
If the dressing roll is produced according to the negative process, then the hard material coating can be applied, but the process is time-consuming and the tool must be produced according to known methods
Solution Approach 1:
The patent incorporates reinforcement features for hard material grain anchoring into the initial mold or master pattern used in the negative process. By pre-configuring the mold with the necessary geometric features or bonding structures in the groove tip regions, the reinforcement is automatically transferred to the dressing roll during production, eliminating the need for separate reinforcement steps and reducing overall production time.
4Duration of action of stationary object
If profiled hard material segments are embedded in the active surface, then the service life is extended, but inhomogeneity arises on the working surface of the dressing tool which impairs the quality of the ground workpiece
Solution Approach 1:
The patent applies profiled hard material segments exclusively to the groove tip regions where they are needed for grain retention, while leaving the groove flanks with their original continuous hard material coating. This localized application of segments ensures that the critical dressing surfaces maintain their homogeneity for producing smooth workpiece surfaces, while the segmented regions provide enhanced grain anchoring where high stress occurs.
Data Source
AI summary
Full profile dressing roll (1) for dressing multi-start grinding worms for the generation grinding of small-module gears, comprising a groove-shaped axial section profile of the outer envelope surface (2), covered with hard material grains, and profile-cut hard-material profile combs (3) embedded in this envelope surface and having a multi-ribbed rack tooth system profile, the profile of which touches the outer envelope surface (2) of the dressing roll (1) only in sections of the axial section profile of the dressing roll (1) which do not participate in the generation of the grinding worm flanks. As a result, the profile sections, highly stressed during the dressing, at the crest and root of the profile grooves (4) are protected from high wear and premature grain loss and the service life of the dressing roll is effectively increased without the inhomogeneity of the flank surface of the dressing roll (1) being disturbed by the profile combs (3).