Multi-axis Chamfering Tool for Gear Flanks
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Solution Overview
Problem
Current gear manufacturing processes, particularly power skiving, require reversing the direction of rotation to chamfer both right and left flanks, leading to longer process times and inefficiencies, especially in series production.
Innovation Solution
A roller-skiving method and specialized tool with CNC-controlled multi-axis capabilities allow for chamfering both right and left flanks without reversing the direction of rotation, utilizing a special tool with first and second rake faces and a cross-axis angle between 10 and 30 degrees for continuous, efficient chamfering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the direction of rotation is reversed to chamfer both right and left flanks, then both flanks can be chamfered, but the process time increases
Solution Approach 1:
The patent applies continuity of useful action by enabling the chamfering tool to process both right and left flanks without reversing the rotation direction. The tool continuously engages with the workpiece, maintaining constant rotational motion while achieving complete chamfering of all tooth flanks through a single-pass operation, thereby eliminating idle time associated with direction reversal.
Solution Approach 2:
Instead of reversing the rotation direction to access both flanks, the patent inverts the approach by keeping the rotation direction constant and using a specially designed tool with multiple cutting edges oriented to engage both right and left flanks simultaneously. This inversion of the conventional method eliminates the need for direction reversal while maintaining full chamfering capability.
2Productivity
If power skiving is used for continuous machining, then productivity increases, but additional process steps are required for chamfering
Solution Approach 1:
The patent merges the chamfering function with the power skiving operation by equipping the skiving tool with additional cutting edges specifically configured for chamfering. This combination allows the same tool that performs the continuous power skiving machining to also execute chamfering operations on all tooth flanks during the same operational cycle, integrating multiple functions into a single tool system.
Solution Approach 2:
The skiving tool is designed with multi-functionality, serving both as a power skiving cutter for tooth generation and as a chamfering tool for edge preparation. The tool incorporates multiple cutting edges with different orientations, enabling it to perform both roughing/finishing skiving operations and chamfering operations without requiring tool changes or additional specialized equipment.
3Manufacturing precision
If a specialized chamfering tool is used, then chamfering quality improves, but the device complexity increases
Solution Approach 1:
The chamfering function is segmented into multiple discrete cutting edges on the tool, with each cutting edge specifically configured to engage a particular flank orientation. This segmentation allows precise control over the chamfering process for each individual flank while maintaining a unified tool structure that integrates with the power skiving operation.
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3B
AI summary
Method for face chamfering of a tooth of a workpiece (20) in a CNC-controlled multi-axis machine, comprising the steps of: - inserting a tool (100) in the multi-axis machine, wherein the tool (100) has at least one cutting tooth (111) with a first rake face and a second rake face, - driving the tool (100) in a first direction of rotation, - performing first CNC-controlled relative movements while the tool (100) rotates in the first direction of rotation to chamfer a first face edge of a first tooth of the tooth with the first rake face of the tool (100), - performing second CNC-controlled relative movements while the tool (100) rotates in the first direction of rotation to chamfer a second face edge of the first tooth or of another tooth of the tooth with the second rake face of the tool (100).