Dual-Spindle Chamfer Machining for Obstructed Toothed Edges
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Solution Overview
Problem
Existing chamfer milling methods, such as the Chamfer Cut method, are limited in machining edges with disturbing contours, leading to tool wear and inefficiency, especially in multiple toothings or toothed shafts, where the Chamfer Cut method cannot be used for all edges due to spatial constraints.
Innovation Solution
An apparatus with a machining head equipped with both a first tool spindle for a chamfer milling cutter and a second tool spindle for an end milling cutter, allowing the end milling cutter to machine edges with disturbing contours, while the chamfer milling cutter handles edges without obstructions, using synchronized NC axes for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If chamfer milling cutters (Chamfer Cut method) are used for chamfering tooth edges, then machining efficiency is improved, but the method cannot be used for edges with disturbing contours due to spatial constraints
Solution Approach 1:
The invention divides the chamfering function into two separate tool spindles: one for chamfer milling cutters (Chamfer Cut method) and another for end milling cutters. This segmentation allows each tool type to be independently selected and positioned based on the specific machining requirements of different tooth edges, resolving the contradiction between efficiency and adaptability.
Solution Approach 2:
The machining head is designed with multi-functionality by incorporating both chamfer milling cutters and end milling cutters in separate tool spindles. This universal design enables the apparatus to handle both accessible edges (using chamfer milling for efficiency) and edges with disturbing contours (using end milling for adaptability), eliminating the limitation of the single-method approach.
2Adaptability or versatility
If end milling cutters are used for chamfering edges with disturbing contours, then adaptability is improved, but machining time increases
Solution Approach 1:
By segmenting the tool spindles into separate units for different cutter types, the system can apply end milling only to the specific edges requiring it (those with disturbing contours), while using faster chamfer milling for other edges. This selective application minimizes overall machining time while maintaining adaptability where needed.
Solution Approach 2:
The invention applies different machining methods to different locations (local areas) of the workpiece based on specific requirements. End milling is applied locally only to edges with disturbing contours where adaptability is critical, while chamfer milling is used for other edges where speed is prioritized, optimizing the balance between adaptability and time consumption.
3Adaptability or versatility
If press deburring is used for blocked tooth edges, then adaptability is improved, but tool wear increases significantly
Solution Approach 1:
The invention replaces the press deburring method (which causes high tool wear) with end milling cutters that are designed for longer service life. The end milling cutters can effectively remove material from blocked edges through their cutting action rather than pressing, significantly reducing tool wear and extending tool longevity while maintaining the ability to machine difficult-to-reach edges.
Data Source
AI summary
The present application relates an apparatus for chamfer-machining at least two edges of a toothed workpiece, wherein the apparatus comprises at least one workpiece spindle with a rotatably mounted workpiece holder for receiving the workpiece and a machining head movable relative to the workpiece holder via at least one axis of movement, wherein on the machining head at least one first tool spindle with a first rotatably mounted tool holder is provided for receiving at least one first chamfer milling cutter for chamfer-machining a first edge of a toothing of a workpiece received in the workpiece holder, wherein on the machining head a second tool spindle with a second rotatably mounted tool holder is provided for receiving an end milling cutter for chamfer-machining a second edge of a toothing of a workpiece received in the workpiece holder.