Dual Threaded Grinding Wheel Layout for Precise Gear Finishing
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Solution Overview
Problem
Conventional threaded grinding wheels with separate rough-finish and finish grinding surfaces in a helical pattern face challenges in maintaining machining accuracy due to potential surface contact issues and difficulty in forming finish surfaces on smaller wheels, limiting the effectiveness of using only one grinding surface for gear machining.
Innovation Solution
A barrel-shaped threaded grinding wheel composed of two types of grinding wheels differing in performance, where one is used for finish grinding and the other for super-finish grinding, with connected end surfaces to ensure flush grinding and sequential use of predefined grinding ranges, allowing for accurate gear machining with a simple configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the rough-finish grinding surface and the finish grinding surface are formed next to each other in the grinding-wheel radial direction, then two types of grinding surfaces are provided in a single wheel, but the widthwise areas of both grinding surfaces are reduced and the other grinding surface may contact the gear causing machining accuracy issues
Solution Approach 1:
The grinding wheel is divided into two separate wheels: a first threaded grinding wheel with a rough-finish grinding surface and a second threaded grinding wheel with a finish grinding surface. These wheels are used sequentially in two distinct grinding steps, eliminating the interference problem that would occur if both surfaces were present on a single wheel while still providing both grinding functions.
2Adaptability or versatility
If the finish grinding surface is formed in the helical rough-finish grinding surface, then a multi-functional grinding surface is created, but it is very difficult to form the finish grinding surface and remarkably so when the threaded grinding wheel itself is small
Solution Approach 1:
Instead of attempting to form a finish grinding surface within the constrained space of a small threaded grinding wheel, the invention segments the grinding function into two separate wheels. This approach eliminates the manufacturing difficulty of forming complex multi-functional surfaces on small wheels while maintaining adaptability through sequential use of appropriately sized grinding wheels.
3Device complexity
If only one grinding surface is used for gear grinding, then the configuration is simple, but the gear machining accuracy cannot be improved sufficiently
Solution Approach 1:
The grinding process is segmented into two sequential steps using two different threaded grinding wheels: rough-finish grinding followed by finish grinding. This segmentation enables sufficient improvement in gear machining accuracy by utilizing the complementary characteristics of each grinding surface type while maintaining operational simplicity through a standardized two-step process.
Solution Approach 2:
The invention establishes a continuous grinding process where the first threaded grinding wheel performs rough-finish grinding and the second threaded grinding wheel performs finish grinding in sequence. This continuous action ensures that the gear progresses through both grinding stages without interruption, achieving high machining accuracy through uninterrupted sequential processing.
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
The solution enables accurate gear grinding with a simple configuration by allowing sequential use of finish and super-finish grinding surfaces, improving machining accuracy and extending the life of the grinding wheels through continuous dressing.
Implementation Method 1
rotating a gear and a threaded grinding wheel in mesh with each other to grind the gear's tooth surfaces with the threaded grinding wheel's grinding surfaces
Data Source
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AI summary
Provided are: a screw-shaped grindstone for grinding gears that has a simple configuration and is capable of grinding gears with high precision; and a method for grinding gears. The screw-shaped grindstone (20) for grinding gears, which grinds a workpiece (W1) by rotating while meshing with the workpiece (W1), comprises a screw-shaped grindstone (21) that grinds the workpiece (W1), and a screw-shaped grindstone (22) that is linked to the screw-shaped grindstone (21) on the same axis, and grinds the workpiece (W1), which has been ground by the screw-shaped grindstone (21). A plurality of grinding ranges (L1, L2) that are sectioned at prescribed lengths in the width direction of the grindstone are established with respect to the screw-shaped grindstones (21, 22), and each grinding range (L1, L2) of the screw-shaped grindstones (21, 22) serves as the range of use per workpiece (W1).