Gear Tooth Chamfering with End Milling for Blocked Edges
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Solution Overview
Problem
Existing chamfering methods, particularly the chamfer-cut process, face challenges when dealing with interfering contours near tooth edges, limiting their applicability to all edges of geared workpieces and leading to high tool wear during deburring.
Innovation Solution
A device with a machining head that includes both a chamfering cutter and an end mill, allowing the end mill to be used for edges inaccessible to the chamfering cutter due to interfering contours, with synchronized movement and adjustable axes for precise engagement and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a chamfering cutter is used to chamfer tooth edges, then processing efficiency is improved, but edges with interfering contours cannot be machined
Solution Approach 1:
The device combines two different chamfering tools (chamfering cutter and end mill) in a single setup, allowing the system to handle both accessible edges (processed by chamfering cutter) and edges with interfering contours (processed by end mill), thereby achieving universal applicability across all tooth edges
Solution Approach 2:
The chamfering process is divided into two segments: edges without interfering contours are processed by the chamfering cutter, while edges with interfering contours are processed by the end mill. This segmentation allows each tool to specialize in its suitable application area, resolving the contradiction between efficiency and versatility
2Adaptability or versatility
If pressure deburring is used for edges blocked by interfering contours, then all edges can be deburred, but tool wear increases significantly
Solution Approach 1:
The end mill is used as a sacrificial tool for processing difficult-to-reach edges. Although the end mill wears faster than the chamfering cutter, it is replaced more easily and cheaply, allowing the expensive chamfering cutter to be protected from excessive wear by not using it on blocked edges
3Speed
If only a chamfering cutter is used, then processing speed is high, but interference contours prevent access to certain edges
Solution Approach 1:
The device merges the chamfering cutter and end mill into a single integrated setup with synchronized rotation, allowing both tools to work on different edges of the same workpiece simultaneously or sequentially, thereby maintaining high processing speed while improving accessibility to all edges
Data Source
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AI summary
The present application relates to a device and a method for chamfering at least two edges (12, 13, 14, 15) of a toothed workpiece (7), wherein the device comprises at least one workpiece spindle with a rotatably mounted workpiece holder (4) for receiving the workpiece and a machining head (3) movable relative to the workpiece holder via at least one axis of movement, wherein at least one first tool spindle with a first rotatably mounted tool holder (1) for receiving at least one first chamfering cutter (6) for chamfering a first edge of a tooth (7a) of a workpiece held in the workpiece holder is provided on the machining head.wherein a second tool spindle with a second rotatably mounted tool holder (2) for receiving a finger milling cutter (8) for chamfering a second edge (14) of a toothing (7b) of the workpiece held in the workpiece holder is provided on the machining head.