Dual-Gear Hard Finishing with Coupled Rotational Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for hard-fine machining of workpieces with multiple gears, especially those with different diameters, face challenges in achieving high accuracy and precision due to the need for interim clamping changes and complex setup procedures, which can lead to inconsistencies and increased reject rates.
Innovation Solution
The method involves maintaining the workpiece on the same spindle with coupled rotational position references, allowing for continuous machining of both gears without clamping changes, using a predetermined rotation angle difference between the gears' tooth gaps to ensure precise alignment and symmetry, and employing non-contact sensors for accurate positioning and tool engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If interim clamping changes are performed for machining different gears, then different machining processes can be applied to each gear, but machining accuracy and precision deteriorate due to setup inconsistencies
Solution Approach 1:
The patent combines multiple machining operations for different gears into a single clamping setup. The workpiece is clamped once and remains clamped throughout the machining of multiple gears, eliminating the need for interim clamping changes. This is achieved by designing a unified machining system that can accommodate different gear types (e.g., external gears and internal gears) simultaneously or sequentially without releasing the workpiece.
Solution Approach 2:
The patent creates a universal machining system that can perform multiple types of machining operations on different gears within a single setup. The machining device is designed to handle various gear configurations (different diameters, tooth directions, machining methods) using the same clamping arrangement, making the system multi-functional while maintaining precision.
2Manufacturing precision
If complex setup procedures are used for initial centering of each gear, then proper tool engagement can be achieved, but time consumption and productivity worsen
Solution Approach 1:
The patent performs preliminary centering and positioning actions during the initial clamping phase, before machining begins. The workpiece is pre-positioned and centered in the clamping device with high precision, and this position is maintained throughout all subsequent machining operations. This eliminates the need for repeated centering and setup procedures for each gear.
Solution Approach 2:
The patent maintains continuous machining operations without interrupting the clamping state. Once the workpiece is clamped and positioned, the machining process continues seamlessly across multiple gears without releasing or repositioning the workpiece. This continuous action eliminates downtime associated with setup changes and maximizes productivity.
3Adaptability or versatility
If multiple clamping operations are performed for different gears, then each gear can be machined independently, but manufacturing cost and complexity worsen due to increased setup requirements
Solution Approach 1:
The patent merges multiple clamping operations into a single clamping action. The clamping device is designed to hold the workpiece in a fixed position that accommodates machining of multiple different gears. This unified clamping approach reduces the number of clamping operations from multiple to one, simplifying the overall process.
Solution Approach 2:
The clamping device is designed as a universal fixture that can accommodate various gear types and configurations within its design parameters. It provides independent machining capability for different gears while maintaining a consistent, simplified clamping mechanism throughout the process.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a method for hard fine machining of two toothings (1, 2) which are provided on a workpiece (4) and are different from each other, in which method, prior to the respective machining operation, in order to adjust a matching tool engagement for the machining operation, a first relative rotational angle position of a first rotational position reference of a first of the toothings relative to a rotational axle position of a workpiece spindle, which holds the workpiece clamped for the first machining operation, and a second relative rotational angle position of a second rotational position reference of the second of the toothings relative to a rotational axle position of a workpiece spindle, which holds the workpiece clamped for the second machining operation, are determined, wherein the machining operations are carried out without intermediate clamping change on the same workpiece spindle and on the basis of the coupled first and second rotational position reference. The invention also relates to a gear cutting machine for hard fine machining of workpieces of this kind, a control device having control instructions for carrying out a method of this kind, hard fine machining combination tools and a sensor assembly therefor.