Gear Blank Chamfer Correction Through Coupled Multi-Axis Control
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Solution Overview
Problem
The existing methods for correcting bevel sizes, shapes, and symmetry on tooth edges produced with a ChamferCut milling cutter, which has a highly asymmetrical profile, are challenging due to the need for precise positional orientation and complex axis adjustments, especially when manufacturing helical gears, where corrections have different effects on pointed and blunt tooth edges.
Innovation Solution
A method that allows for semi-automatic and fully automatic correction of chamfer geometry by calculating additional axis movements using trigonometric functions based on measured or entered data, enabling precise adjustments in the Z1, C1, and Y1 axes to achieve correct chamfer size, shape, and symmetry, even in complex gear geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a ChamferCut milling cutter with highly asymmetrical profile is used to create chamfers on gear tooth edges, then the entire contour of the chamfer (both flanks and tooth root) can be created in a single cut, but the tool requires precise alignment between the workpiece and the cutter with complex axis adjustments
Solution Approach 1:
The patent replaces manual mechanical alignment procedures with an automated measurement and calculation system. A measurement device captures actual chamfer geometry, and a control system automatically calculates correction values for axis positions, eliminating complex manual alignment operations while maintaining single-cut productivity
Solution Approach 2:
The system performs self-correction by automatically measuring the produced chamfer and calculating the necessary axis adjustments. The control system uses the measurement data to determine correction values without requiring external intervention or complex manual realignment procedures
2Manufacturing precision
If correction values are manually determined and setting data is modified based on measured values, then chamfer geometry can be corrected, but the process becomes time-consuming and difficult especially for helical gears where corrections have different effects on sharp and blunt tooth edges
Solution Approach 1:
The patent replaces manual measurement and calculation processes with an automated measurement device and control system. The device automatically captures chamfer geometry and the control system calculates correction values, eliminating time-consuming manual operations while maintaining precision for complex helical gear geometries
Solution Approach 2:
The system implements a feedback loop where the measurement device continuously monitors chamfer geometry and the control system automatically adjusts axis positions based on measured deviations. This closed-loop control rapidly converges to the correct chamfer dimensions without requiring multiple manual trial-and-error iterations
3Manufacturing precision
If multiple tests are conducted to determine which modified settings produce correct tooth chamfer, then the theoretically correct setting data can be entered into the machine control system, but the process becomes very difficult when many axes are involved
Solution Approach 1:
The patent replaces multiple manual tests and trial-and-error adjustments with an automated measurement and calculation system. The measurement device captures actual chamfer geometry and the control system automatically determines the correct settings for all involved axes, eliminating the complexity of manual multi-axis adjustment
Solution Approach 2:
The patent introduces a control system as an intermediary between the measurement device and the machine axes. This intermediary automatically processes measurement data and calculates the coordinated adjustments needed for multiple axes, simplifying the complex interaction between numerous axes and measurement parameters
Data Source
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AI summary
The invention relates to a method for deburring a gear blank and in particular to a method for correcting chamfer sizes, chamfer shapes and chamfer symmetry on tooth edges that were produced with a deburring cutter with a highly asymmetrical tooth shape (ChamferCut), with a semi-automatic correction of the chamfers, i.e. the chamfer width and chamfer shape , by coupling the movement of several axes of a gear cutting machine, which has at least a workpiece rotation axis as a C1 axis, the spatial displacement axes of a tool slide as Z1, X1 and Y1 axes and the displacement direction in the axial direction of the tool axis as the V1 direction, with the following Steps: - Specification of the correction in one axis direction, - Calculation of the necessary correction amount for other axes by the control for - Coupling the C1 axis to the Z1 axis via the helix angle of the gearing and/or - Coupling the C1 and Z1 axes to the V1 direction via the swivel angle of the tool and nd the front pressure angle of the gearing and/or - coupling of the Y1 - axis to the C1 - axis via the front pressure angle of the gearing, and a device for the automatic implementation of the method.