Profile Tool Pivoting Angle for Gear Flank Machining
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Solution Overview
Problem
Existing methods for machining gearing tooth flanks that deviate from target geometry due to allowances require complex process steps and increased time, with uneven material removal leading to potential overheating risks.
Innovation Solution
The method involves setting the profile tool to a pivoting angle that deviates from its design angle in at least one infeed step before the last, creating an enlarged engagement area without reprofiling the tool, allowing for more uniform material removal and reduced processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the profile tool is set to the design angle in all infeed steps, then the tool profile matches the target geometry, but the engagement area is small in early infeed steps leading to uneven material removal and overheating risks
Solution Approach 1:
The patent applies dynamics by making the tool pivot angle adjustable during the machining process. The pivot angle is dynamically changed between infeed steps: set to a first angle (different from design angle) in early infeed steps to maximize engagement area and material removal, then transitioned to the design angle in the final infeed step to achieve precise target geometry. This dynamic adjustment resolves the contradiction between productivity and manufacturing precision.
2Productivity
If the profile tool is reprofiled after each infeed step to achieve even material removal, then material removal uniformity improves, but the process complexity and machining time increase
Solution Approach 1:
The patent applies parameter changes by modifying the pivot angle parameter instead of reprofiling the tool. The pivot angle is changed between infeed steps to control engagement area and achieve uniform material removal, while the tool profile itself remains unchanged. This approach maintains productivity improvement while avoiding the complexity and time cost of repeated tool reprofiling operations.
3Productivity
If multiple grinding wheels are used with different profiles for different infeed steps, then material removal uniformity improves, but the device complexity and time expenditure increase
Solution Approach 1:
The patent applies universality by making a single profile tool perform multiple functions through pivot angle adjustment. The same tool, used with different pivot angles in different infeed steps, achieves both high material removal rates (with larger engagement area) and precise final geometry (with design angle), replacing the need for multiple specialized grinding wheels and reducing total machining time.
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 achieves more even material removal over the flank height with reduced risk of overheating and faster production, without the need for tool reprofiling or additional tools, effectively addressing the inefficiencies of prior methods.
Implementation Method 1
the profile tool in a setting dependent on the pivot angle between the plane of rotation of the tool orthogonal to the tool axis and the toothing axis relative to the toothing is brought into a machining engagement with it, in which material is removed in the engagement area
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3d
AI summary
The method involves extending an engaging portion with a profile tool over complete flank height, where the tool is adjusted to a pivoting angle determined by a design of the tool. Material removal guided to a target geometry is caused. The tool is adjusted to the pivoting angle, which is deviated from a design angle of the tool such that the pivoting angle results in the engaging portion, which is enlarged against the adjustment of the design angle along direction of the flank height. The pivoting angle is selected based on a parameter of the design angle and/or inclination angle. Independent claims are also included for the following: (1) a machine tool for processing a gearing (2) a computer program product comprising a set of instructions for controlling a machine tool.