Dual-Toothing Hard Finishing With Coupled Rotational References
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for hard finishing 'dumbbell-shaped' workpieces with two different toothings, where one gearing body acts as a shoulder for the other, face challenges in achieving high accuracy due to the need for separate clamping and machining processes, limiting precision and efficiency.
Innovation Solution
The method involves machining both toothings on the same workpiece spindle without clamping changes, with coupled rotational position references to maintain symmetry and precise rotational angle differences, using sensors to detect tooth gaps and markings for accurate positioning, allowing for continuous machining with minimal tolerance deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate clamping and machining processes are used for each toothing, then each toothing can be machined independently, but manufacturing precision and efficiency deteriorate due to repeated clamping changes and positioning errors
Solution Approach 1:
The patent combines multiple toothings on a single workpiece that can be machined simultaneously or sequentially without changing the clamping. The workpiece includes a first toothing and a second toothing arranged such that both can be accessed by the machining tool from the same clamping position, eliminating the need for re-clamping and thereby maintaining high positioning precision while improving productivity
Solution Approach 2:
The workpiece is segmented into multiple independent toothings (first toothing and second toothing) that are spatially separated but mechanically connected through the same workpiece body. This segmentation allows each toothing to be machined independently while maintaining the same clamping reference, resolving the contradiction between independent machining capability and positioning accuracy
2Manufacturing precision
If the larger toothing is hard-finished by generating grinding and the smaller toothing is honed, then different machining methods can be applied to suit different sizes, but device complexity and process time increase due to multiple machining operations
Solution Approach 1:
The patent employs a dynamically adjustable machining system where the same machining tool can adapt its parameters and engagement mode to suit different toothing sizes. The machining process can switch between generating grinding for larger toothings and honing for smaller toothings without changing the fundamental tooling setup, thereby reducing device complexity while maintaining surface finish quality
Solution Approach 2:
The machining tool is designed with multi-functionality to perform both generating grinding and honing operations. By making the tool capable of executing multiple machining methods, the patent eliminates the need for separate specialized tools for each toothing size, thereby reducing device complexity while maintaining the ability to achieve high surface finish quality appropriate for each toothing type
Data Source
AI summary
A method for hard finishing two different toothings on a workpiece, wherein, prior to each machining process, to set the correct tool engagement position for the machining process, a first relative rotational angle position of a first rotational position reference of the first toothing is determined relative to an axial rotational position of the workpiece spindle holding and clamping the workpiece for the first machining, and a second relative rotational angle position of a second rotational position reference of the second toothing is determined relative to an axial rotational position of a workpiece spindle holding and clamping the workpiece for the second machining, wherein the machining operations are carried out on the same workpiece spindle with no intervening clamping change, and with the first and second rotational position references coupled to each other as the basis thereof.