Gear Grinding Method Using Tooth Deviation Measurements
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Solution Overview
Problem
Conventional gear grinding methods face issues with machining accuracy due to thermal stress-induced strain in gears, leading to deep cutting and potential grinding burns, or no-contact situations that waste time and reduce efficiency.
Innovation Solution
A gear grinding method that sets the initial cutting position of the grinding wheel based on tooth thickness deviation measurements, ensuring the wheel does not cut too deeply and avoids no-contact situations by controlling the rotation and feed of the gear and grinding wheel, using multiple measurement points to determine optimal cutting positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the initial cutting position is set to ensure the grinding wheel does not cut too deeply, then machining accuracy is improved, but the grinding wheel may fall into a no-contact state when gear strain is large, leading to loss of machining time
Solution Approach 1:
The patent measures tooth thickness deviations before grinding and uses these measurements to pre-calculate and set the optimal initial cutting position. This preliminary action ensures that the grinding wheel starts at the correct position, avoiding both deep cutting and no-contact situations, thus resolving the contradiction between machining accuracy and machining time
Solution Approach 2:
The patent implements a feedback mechanism where tooth thickness deviations are measured, processed to determine the appropriate initial cutting position offset, and then applied to control the grinding operation. This closed-loop feedback ensures optimal grinding parameters are selected based on actual gear conditions, preventing both over-cutting and air cutting
2Productivity
If the initial cutting position is set for normal grinding operations, then machining efficiency is maintained, but the grinding wheel may cut into the tooth surface too deeply due to gear strain, causing grinding burns and reducing machining accuracy
Solution Approach 1:
The patent performs preliminary measurement of tooth thickness deviations before grinding and uses this information to pre-determine the optimal initial cutting position. This preliminary action allows the system to adjust the cutting position in advance based on actual gear strain conditions, preventing deep cutting and grinding burns while maintaining efficient machining
Solution Approach 2:
The patent dynamically adjusts the initial cutting position parameter based on measured tooth thickness deviations. By changing this critical parameter according to actual gear conditions rather than using a fixed position, the system prevents deep cutting and grinding burns while maintaining high machining efficiency
Data Source
AI summary
Provided is a gear grinding method wherein an initial cutting position by a grindstone is appropriately set, resulting in an improvement being able to be made in machining accuracy. For this purpose, the gear grinding method is such that rotation of a workpiece (W) about a workpiece rotation axis (C), cutting by a grindstone (15) in the X-axis direction, and feeding of the grindstone (15) in the Z-axis direction are controlled, resulting in the workpiece (W) being ground by the grindstone (15). In this method, measurement points (P1-P9) are set in a grid-like pattern on a left tooth surface (WL) and a right tooth surface (WR) of a predetermined tooth (Wa) of the workpiece (W); rotation phases about the workpiece rotation axis (C) at the measurement points (P1-P9) are detected; tooth thickness deviation amounts (e) between a reference involute tooth surface and the measurement points (P1-P9) on the left and right tooth surfaces, as well as tooth thickness deviation amounts (e) between the involute tooth surface and corresponding points (Q1-Q9) on all teeth other than the tooth (Wa), are obtained on the basis of the detected rotation phases; and an initial cutting position (X1) for the grindstone (15) is set on the basis of the largest of the deviation amounts (e).