Gear Chamfering and Deburring Apparatus with Auxiliary Spindle
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Solution Overview
Problem
Existing gear cutting and grinding machines face inefficiencies due to the need for separate chamfering and deburring processes, which slow production and lack flexibility in modifying chamfer sizes or shapes, especially for continuous indexing processes like face hobbing.
Innovation Solution
A gear processing machine equipped with a chamfering and deburring apparatus and an auxiliary spindle, allowing for simultaneous cutting, chamfering, and deburring through a transfer mechanism that loads and unloads workpieces, enabling continuous operation and increased machine output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If chamfering is performed separately after gear cutting, then the gear can be properly chamfered and deburred, but production time increases and machine output decreases
Solution Approach 1:
The patent combines the chamfering apparatus with the gear cutting machine, integrating two separate processes into one unified system. The chamfering tool is positioned adjacent to the cutting tool, allowing both operations to be performed on the same workpiece in sequence without removal, thereby resolving the contradiction between achieving proper chamfer quality and maintaining high productivity
2Productivity
If chamfering is performed while the gear remains on the work spindle, then non-cutting time is reduced, but the system lacks flexibility for modifying chamfer size, extent or shape
Solution Approach 1:
The chamfering tool is designed with adjustable parameters including variable chamfer angles, adjustable chamfer lengths, and programmable tool paths through CNC control. This dynamic adjustability allows the system to maintain high productivity while providing full flexibility to modify chamfer size, extent, and shape according to different production requirements
3Device complexity
If a fixed chamfering mechanism is used, then the structure is simple, but it cannot chamfer gears produced by continuous indexing processes
Solution Approach 1:
The chamfering apparatus incorporates a universal positioning system and programmable control that can accommodate both discrete indexed gears and continuous indexing processes. The tool can be programmed to follow the workpiece through continuous rotation, and the positioning system can adapt to different indexing methods, providing multi-functionality that resolves the contradiction between structural simplicity and process compatibility
Data Source
AI summary
Gear processing machine (4), such as a gear cutting or grinding machine, wherein a chamfering and/or deburring apparatus (2) and auxiliary spindle (10) are included on the same machine. A transfer mechanism (8) loads, unloads and transfers workpieces between a machining spindle (6) and the auxiliary spindle (10) thereby enabling simultaneous cutting and chamfering and/or deburring processes to be carried out. Via the auxiliary spindle, completed workpieces may be removed from the machine and blank workpieces may be loaded into the machine while another gear is being processed on the machine spindle thereby enhancing machine output and creating a more efficient operation.