Phase-Shifted Gear Cutting for Independent Tooth Tip Machining

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Solution Overview

Problem

Existing gear machining methods lack flexibility and precision in shaping tooth tips independently of the foot region, often requiring additional tools and resulting in positioning errors during subsequent machining steps.

Innovation Solution

A phase-shifted machining engagement is introduced, where the tool toothing is positioned at least one-fourth of the pitch beyond the initial gear coupling, allowing for independent machining of tooth tips without additional tools, maintaining the same rotation axis reference and enabling precise control of the tip diameter through contact lines and axial movements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If regular gear coupling machining is used, then the foot region of the workpiece toothing is shaped by the tool toothing, but the tooth tips cannot be machined independently and additional tools are required

Engineering Contradiction:

Improveindependent machining capability of tooth tipsVSAvoidnumber of tools required

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies dynamics by introducing a phase shift to the gear coupling relationship between the tool toothing and workpiece toothing. The phase shift varies during the machining process, allowing the tool to transition from shaping the foot region to machining the tooth tips independently, eliminating the need for additional tools while maintaining continuous engagement.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes the phase shift parameter of the gear coupling to enable different machining functions. By adjusting the phase shift, the same tool can perform both foot region shaping and independent tooth tip machining, resolving the contradiction between adaptability and device complexity.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If different tools are used for tooth tip machining, then independent machining is achieved, but positioning errors occur during subsequent machining steps

Engineering Contradiction:

Improvepositioning accuracyVSAvoidmachining function flexibility

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent makes the same tool toothing perform multiple functions by introducing phase shift. The tool can machine both the foot region and tooth tips independently while maintaining the same reference rotation axis, ensuring positioning accuracy for subsequent machining steps without sacrificing machining function flexibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

By dynamically adjusting the phase shift during machining, the same tool adapts to different machining requirements (foot region shaping and tooth tip machining) while maintaining a consistent reference frame, thereby achieving both versatility and positioning precision.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If phase-shifted machining engagement is used, then tooth tips can be machined independently with the same tool, but the machining distance increases

Engineering Contradiction:

Improveindependent tooth tip machiningVSAvoidmachining distance

Core Design Contradiction:

Adaptability or versatilityVSLength of moving object

Solution Approach 1:

The patent applies partial action by using the phase-shifted engagement only when tooth tip machining is required, rather than continuously. The machining distance is increased only to the extent necessary to achieve the phase shift, minimizing the additional movement while enabling independent tooth tip machining capability.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS20230264280A1Method for machining and producing a toothed portion on a workpiece

Publication Date: 2023.08.24 GLEASON PFAUTER MASCHFAB

AI summary

the invention relates to a method for machining or producing a toothed portion (2) on a workpiece by means of a tool toothed portion (4), wherein the tool toothed portion is brought into a first machining engagement with the rotating workpiece toothed portion clamped in a clamped setup, such that there is rolling coupling which assigns the teeth of the tool toothed portion to the tooth spaces of the workpiece toothed portion, and wherein the tool toothed portion is brought into a second machining engagement phase-shifted by at least one fourth of the pitch in comparison with the rolling coupling of the first machining engagement at the machining distance of deepest advancement, said second machining engagement having increased machining distance from the workpiece toothed portion clamped in the same clamped setup of the first machining engagement in comparison with the deepest advancement of the first machining engagement. The invention also relates to a control program having control instructions, which, when executed on a controller of a gear cutting machine, cause said gear cutting machine to carry out the method. The invention also relates to a gear cutting machine therefor.