Gear Cutting Machine Waviness Correction for Noise Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing noise-optimized gears are inadequate in achieving uniform rotational movement and minimizing vibration excitation in transmissions, as they require labor-intensive modifications and are inflexible for mass production, especially in implementing microcorrections like flank waviness.
Innovation Solution
A method that measures the rotational distance error of gears under load and uses this data to calculate and implement periodic waviness on tooth flanks through advanced machining programs and tools, ensuring uniform contact and reduced noise excitation by adjusting material removal and addition based on engagement and disengagement shocks, and using tools with variable engagement angles and wobble movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional gear machining methods are used, then production process is simple, but manufacturing precision of tooth flank geometry is insufficient for noise optimization
Solution Approach 1:
The patent applies preliminary action by pre-calculating the required tooth flank modifications using simulation programs that model the transmission's noise behavior. The calculated correction values are then integrated into the CNC machining program before actual machining, allowing the gear-cutting machine to directly transfer the optimized geometry onto the tooth flanks without requiring complex intermediate steps or specialized tooling.
Solution Approach 2:
The patent replaces complex mechanical modification processes with a computational approach. Instead of using complex mechanical devices to physically modify tooth flanks, the system uses calculation programs to determine the required modifications and CNC control software to guide the machining process, substituting mechanical complexity with computational precision.
2Manufacturing precision
If profiling gear with 3D corrections is used, then tooth flank corrections can be transferred, but modifications are labor-intensive and inflexible for mass production
Solution Approach 1:
The patent uses copying by transferring the calculated tooth flank modifications directly through CNC control software to the gear-cutting machine's motion control. Instead of physically creating a profiling gear as a master template (which would require labor-intensive modifications), the digital correction data is copied and applied programmatically, enabling rapid and flexible reproduction of the optimized geometry across mass production runs.
Solution Approach 2:
The patent applies dynamics by making the machining process adaptable through CNC control. The machining program can be dynamically adjusted based on the calculated correction values, allowing the system to flexibly implement different modification patterns without requiring physical reconfiguration of tooling or fixtures, thus maintaining both precision and productivity in mass production.
3Manufacturing precision
If diagonal gear cutting with continuous angle variation is used, then interleaving corrections are produced, but additional axial movements and surface modifications are required
Solution Approach 1:
The patent merges multiple machining functions into a single integrated CNC-controlled process. Instead of requiring separate operations for diagonal cutting, axial movements, and surface modifications, the system combines all these functions into one coordinated machining program that simultaneously controls the tool's angular position, axial movement, and material removal, thereby achieving interleaving corrections without additional complex steps.
Solution Approach 2:
The patent applies universality by designing the gear-cutting machine's CNC control system to perform multiple functions through a single programming interface. The same control software that manages the basic gear cutting also handles the diagonal cutting angles, axial movements, and surface modifications, making the machine universally capable of producing all required tooth flank corrections through one integrated process.
Data Source
AI summary
The present invention relates to a method for hard-fine machining of tooth flanks with corrections and/or modifications on a gear-cutting machine, wherein respective toothed wheel pairings which mesh with one another within a transmission or a test device are machined while taking account of the respective mating flanks, and wherein the tooth flanks of the relevant workpieces are provided with periodic waviness corrections or waviness modifications. In accordance with the invention, the rotational error extent is determined by means of rotational distance error measurement of the toothed wheel pairs in a gear measuring device and/or transmission. This measurement result serves as an input value for defining the amplitude, frequency and phase position for the periodic flank waviness corrections on the tooth flanks of the toothed wheel pairings for production in the gear-cutting machine.