Gear Toothing Finishing with Elastic Tools After Shot Blasting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing workpieces with toothing or profiling, such as gears, often result in suboptimal surface quality and strength due to hardening distortions and material removal issues during fine machining, requiring additional costly processes like vibratory grinding to maintain geometry and surface quality.
Innovation Solution
Incorporating a second tool with a significantly lower elastic modulus, made of materials like polyurethane or rubber, for repeated hard fine machining after shot blasting, allowing for precise compensation of geometric errors without damaging the hardened layer, and using a polishing-grinding process with elastic tools to maintain surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If shot blasting is used to reinforce the toothing or profile, then the strength is increased, but the surface quality deteriorates
Solution Approach 1:
The patent changes the material parameter (elastic modulus) of the machining tool from rigid materials like steel or ceramic to elastic materials like polyurethane or rubber. This parameter change allows the tool to adapt to surface irregularities created by shot blasting, maintaining contact with the workpiece and achieving the desired surface quality without removing the hardened layer.
2Manufacturing precision
If grinding or honing is used to improve surface quality after shot blasting, then the surface quality is improved, but the hardened layer is removed
Solution Approach 1:
The patent changes the elastic modulus parameter of the tool material to create a softer, more compliant tool that can polish and smooth the surface without cutting or removing material. The elastic material deforms under contact pressure, allowing it to conform to and polish the surface rather than abrasively remove it.
Solution Approach 2:
The patent replaces the traditional mechanical cutting action of grinding or honing with an elastic deformation-based polishing action. Instead of using rigid abrasive tools that cut material, the patent uses elastic tools that deform and polish the surface through controlled deformation and friction.
3Manufacturing precision
If rigid tools are used for hard fine machining, then the machining precision is achieved, but the hardened layer is damaged or removed
Solution Approach 1:
The patent fundamentally changes the elastic modulus parameter of the tool material from high (rigid) to low (elastic). This allows the tool to maintain machining precision through elastic deformation and conformal contact while being soft enough to polish rather than cut the hardened surface layer.
4Device complexity
If alignment processes are performed with limited accuracy, then the manufacturing complexity is reduced, but the stock removal increases
Solution Approach 1:
The patent changes the tool material parameter to elastic materials that can accommodate alignment errors through deformation. The elastic tool body can deflect and conform to the workpiece geometry, allowing accurate machining even when initial alignment is not perfect, thereby reducing the need for excessive stock removal to compensate for misalignment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures high surface quality and strength of the workpiece while reducing process costs by eliminating the need for vibratory grinding and preserving the hardened layer, achieving precise geometry without material removal.
Implementation Method 1
the tool has a base body which has a first elastic modulus; the second tool having a base body which has a second elastic modulus which is at most 33%, preferably at most 25%, of the first elastic modulus
Implementation Method 2
Reinforcement of at least a section of the workpiece by carrying out a shot blasting process
Data Source
AI summary
A method for producing a workpiece having a toothing or profiling, including the steps: a) soft machining the workpiece to produce the toothing or profiling; b) hardening the toothing or profiling; c) hard fine machining the toothing or profiling with a first tool that is a grinding worm, a grinding wheel or a honing wheel, wherein the first tool has a base body with a first elastic modulus; d) reinforcement of at least a section of the workpiece by shot blasting; and, following step d), e) repeated hard fine machining of the toothing or profiling with a second tool that is a grinding worm, a grinding wheel, a set of grinding wheels or a honing wheel. The second tool has a plastic or rubber base body with a second elastic modulus which is at most 33% of the first elastic modulus.