Collision-Contour Gear Grinding Tool With Bonded Abrasive Layer
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Solution Overview
Problem
Existing gear grinding tools with dressable cutting materials face limitations in tool diameter and coating thickness due to collision constraints, restricting their use in hard fine machining of workpieces with interference contours, leading to inefficiencies and economic constraints.
Innovation Solution
A grinding tool design where the dressable grinding layer is glued directly onto the tool mandrel, eliminating the need for a grinding worm sleeve and side stops, allowing for a smaller outside diameter and sufficient coating thickness for repeated dressing cycles, enabling flexible and economical machining of workpieces with collision contours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a conventional tool design with mandrel/flange and lateral fasteners is used, then the tool has sufficient stability and rigidity, but the tool diameter cannot be reduced below the mandrel/flange diameter, limiting usability for collision contours
Solution Approach 1:
The invention extracts and eliminates the mandrel/flange structure and lateral fasteners from the tool design. By removing these conventional mounting components, the tool diameter can be reduced to the minimum required for collision-free machining, while the grinding wheel itself serves as the mounting platform for the abrasive layer.
Solution Approach 2:
The invention transitions from a lateral mounting approach (using mandrel/flange with side fasteners) to an axial mounting approach where the abrasive layer is applied directly to the grinding wheel surface. This dimensional change in the mounting strategy enables smaller tool diameters while maintaining stability through direct bonding.
2Length of moving object
If the tool diameter is reduced to avoid collisions, then the tool can machine collision contours, but the coating thickness becomes insufficient for repeated dressing cycles, reducing economic viability
Solution Approach 1:
The invention changes the bonding method from mechanical fastening to chemical bonding (adhesive bonding), which enables sufficient coating thickness to be achieved and maintained on the grinding wheel surface. This parameter change in the bonding mechanism allows the coating to withstand repeated dressing cycles even on tools with reduced diameter.
3Quantity of substance
If dressable grinding tools are used with sufficient coating thickness, then repeated dressing cycles are economically viable, but the tool diameter increases due to conventional mounting requirements, causing collisions with workpiece contours
Solution Approach 1:
By removing the mandrel/flange structure and lateral fasteners, the tool diameter is minimized to only what is necessary for the grinding operation itself. This extraction of unnecessary structural elements eliminates collisions with workpiece contours while preserving sufficient coating thickness through direct axial bonding of the abrasive layer to the grinding wheel.
4Strength
If a multi-part tool with support ring and grinding element is used, then deformation resistance is improved, but the space required for functional elements increases, preventing reduction of tool diameter
Solution Approach 1:
The invention merges the support structure and grinding element into a single integrated unit where the grinding wheel itself serves as both the support and the functional grinding surface. This eliminates the need for separate support rings and mounting flanges, reducing tool volume while maintaining sufficient deformation resistance through the bonded abrasive layer configuration.
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 design allows for smaller tool diameters, enabling economical and flexible production of workpieces with collision contours, and supports various grinding processes, including those previously not economically viable, by ensuring necessary rigidity and coating thickness.
Implementation Method 1
the dressable grinding layer is glued directly onto the tool mandrel
Data Source
Figure 1
Figure 2
Figure 3a~3d
AI summary
The tool has a dressable grinding tool fixed to a tool holder, where maximum diameter of the tool is limited at a workpiece by collision contours. The dressable grinding tool comprises a one-piece sleeve that is bonded to the tool holder. The dressable grinding tool comprises two circular segments that are adhesively bonded to the tool holder. The tool holder comprises a tool mandrel and a receiving sleeve. The dressable grinding tool comprises two areas with different surface specifications as grains and binders. A tool receiver arbor is provided with two regions. An independent claim is also included for a tool arrangement.