Gear Cutting Machine Integrating Deburring and Recess Machining
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Solution Overview
Problem
Current metal-cutting methods, such as skiving and hobbing, face inefficiencies in total machining time due to the need for separate processes and locations for additional workpiece processing, especially at high workpiece speeds, which increases overall production time.
Innovation Solution
A method and gear cutting machine configuration that allows for parallel machining with a machining tool movable radially and axially relative to the workpiece axis, enabling simultaneous processing of gear teeth and deburring, as well as internal machining, with a control program controlling the machine axes for optimal cutting performance across various axis crossing angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate processes and locations are used for additional workpiece processing, then machining specialization is maintained, but total machining time increases
Solution Approach 1:
The patent combines multiple machining operations (gear tooth cutting, deburring, and recess machining) into a single integrated machining process. The gear cutting machine is equipped with both a toothed tool for gear production and an additional machining tool for deburring and recess creation, allowing all operations to be performed simultaneously in one location rather than requiring separate processes and locations.
Solution Approach 2:
The gear cutting machine is designed with multi-functionality, capable of performing gear tooth cutting, deburring, and recess machining operations. The machine includes a toothed tool for primary gear production and an additional machining tool that can perform secondary operations, making the machine universal for multiple machining tasks in a single setup.
2Productivity
If high workpiece speeds are used for machining, then cutting efficiency improves, but additional processing becomes difficult
Solution Approach 1:
The patent merges gear tooth cutting and additional machining operations into a single simultaneous process. The additional machining tool is positioned and controlled to perform deburring and recess machining while the workpiece rotates at high speed during gear cutting, eliminating the need to reduce speed for secondary operations.
Solution Approach 2:
The gear tooth cutting operation is performed first at high speed, and the additional machining tool simultaneously performs deburring and recess creation during the same high-speed machining window. This preliminary action approach allows additional processing to occur during the primary machining operation rather than requiring a separate, slower operation afterward.
3Loss of time
If multiple tools are used for simultaneous machining, then total processing time reduces, but machine complexity increases
Solution Approach 1:
The patent combines multiple machining functions into a single integrated machine system. The gear cutting machine incorporates both a toothed tool for gear production and an additional machining tool for deburring and recess machining, with a control device that coordinates both tools to operate simultaneously on the workpiece.
Solution Approach 2:
The machine is designed with multi-functionality, where a single gear cutting machine can perform gear tooth cutting, deburring, and recess machining operations. This universal machine approach consolidates what would otherwise require multiple separate machines into one system, reducing total processing time while managing complexity through integrated control.
Data Source
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AI summary
The invention relates to a method for cutting or machining gear teeth of a workpiece which is driven to rotate at very high speeds about its axis of rotation, using a toothed tool which is driven to rotate about its axis. The tool and the workpiece are brought into rolling engagement of the gear teeth between their rotational axes at a crossed-axes angle unequal zero like a helical bevel gear drive, the workpiece and/or its gear teeth being further machined during said tooth engagement.