Dressing Tool Topography Measurement via Plunging Body Transfer
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Solution Overview
Problem
Current methods are inadequate for accurately measuring the geometry of dressing tools in grinding machines, leading to potential wear and damage issues that can affect the quality of the grinding process and result in unsuitable gear wheels.
Innovation Solution
A method involving a CNC-controlled grinding machine that uses a plunging body to transfer and scan the topography of the dressing tool, allowing for precise determination of its actual geometry and wear, enabling timely intervention and optimized dressing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional measurement methods are used for dressing tool geometry, then the measurement process is simple, but the measurement precision is insufficient to detect wear and damage accurately
Solution Approach 1:
The patent introduces a plunging body as an intermediary medium that receives the topography transfer from the dressing tool. This plunging body serves as a mediator that can be scanned by coordinate scanning sensors, enabling precise measurement of dressing tool geometry without directly measuring the dressing tool itself. The plunging body acts as a transfer medium that captures the geometric deviations and makes them measurable.
Solution Approach 2:
The patent creates a negative topography copy of the dressing tool surface by transferring the topography onto the plunging body. This copying process allows the actual geometry of the dressing tool to be reproduced and measured indirectly. The coordinate scanning sensor scans this copied topography on the plunging body, providing precise measurement data about the dressing tool's condition without requiring direct contact with the dressing tool's abrasive surface.
2Reliability
If the dressing tool is used continuously without monitoring, then the productivity is maintained, but the reliability of the grinding process deteriorates due to undetected wear and damage
Solution Approach 1:
The patent implements preliminary monitoring by periodically measuring the dressing tool geometry using the plunging body transfer method and coordinate scanning sensors. This allows wear and damage to be detected before they significantly affect grinding quality. The system performs measurements in advance during machining pauses, enabling timely intervention and dressing tool replacement before reliability deteriorates.
Solution Approach 2:
The patent establishes a feedback loop where the measured topography deviations of the dressing tool are used to determine when dressing or replacement is needed. The coordinate scanning sensor provides continuous feedback about the dressing tool's condition, allowing the system to adjust the dressing schedule and maintain reliable grinding operations. This feedback mechanism prevents both premature replacement and operation with worn tools.
3Measurement precision
If the topography of the dressing tool is transferred to the plunging body during machining pauses, then the measurement accuracy is improved, but the productivity is temporarily reduced due to additional process steps
Solution Approach 1:
The patent implements periodic measurement cycles where the topography transfer and scanning process is performed at predetermined intervals or after a certain number of dressing operations. This periodic action allows measurements to be taken during planned pauses in machining, minimizing the impact on overall productivity. The system balances measurement frequency with production requirements, performing measurements when the machining process is temporarily halted anyway.
Solution Approach 2:
The patent performs the topography transfer to the plunging body in advance during machining pauses, so that measurements are ready before they are needed. This preliminary preparation of measurement data allows the actual analysis and decision-making about dressing or replacement to occur without interrupting the machining flow, thereby minimizing productivity loss.
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 allows for precise monitoring of dressing tool wear, preventing flawed grinding and improving machining accuracy, reducing rejects, and extending dressing tool replacement intervals, leading to more efficient and cost-effective grinding operations.
Implementation Method 1
executing a relative plunging movement to plunge the transfer region of the grinding tool into the material of the plunging body, wherein during the execution of the relative plunging movement, a transfer of the topography of the transfer region into the plunging body in the form of a negative topography is performed
Data Source
AI summary
The invention relates to a method for ascertaining topography deviations of a dressing tool. The method includes executing a predefined relative movement of a dressing tool in relation to a dressable grinding tool, wherein during the execution of the relative movement, at least one contour region of the dressing tool is transferred into a transfer region of the grinding tool. A plunging body made of material which can be ground in the machine is provided. The transfer region of the grinding tool is moved into the vicinity of the plunging body by a relative infeed movement. A rotational movement of the grinding tool around an axis of rotation is executed. Plunging the transfer region of the grinding tool into the material of the plunging body, to thus perform a transfer of the topography of the transfer region into an imaging region of the plunging body. A scanning movement of the topography is performed of the plunging body using a coordinate scanning sensor and a computational ascertainment by means of a computer of at least one item of coordinate information, which permits a statement about the actual geometry of the dressing tool.