Gear Tooth Flank Grinding With Axial Feed Rate Compensation
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Solution Overview
Problem
Existing grinding methods for gear wheels are imprecise and inefficient due to constant feed rates that do not account for variations in actual oversize across the tooth flanks, leading to variable tool wear and thermal damage, and result in unsatisfactory grinding outcomes.
Innovation Solution
The grinding process is optimized by defining a variable feed rate curve that changes with the direction of the axis of rotation, based on measurements of the actual oversize at multiple axial positions, ensuring a constant material removal rate without altering the infeed or number of strokes, using sensors such as lasers or capacitive sensors to adaptively control the feed rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a constant feed rate is used during grinding, then the machining process is simple and stable, but the material removal rate varies due to fluctuations in allowance, leading to variable tool wear and thermal damage
Solution Approach 1:
The patent applies dynamics by transitioning from a constant feed rate to a variable feed rate that adapts to the actual allowance distribution. The feed rate is dynamically adjusted based on measured allowance values at different axial positions, ensuring optimal material removal rate while preventing tool wear and thermal damage. This is achieved through real-time measurement and control system integration.
Solution Approach 2:
The patent implements feedback by using measurement systems to detect the actual allowance on tooth flanks and using this information to adjust the feed rate during grinding. The measured allowance values serve as feedback signals that trigger corresponding feed rate changes, creating a closed-loop control system that optimizes the grinding process based on actual workpiece conditions.
2Productivity
If the feed rate is varied to compensate for allowance fluctuations, then the material removal rate can be optimized, but this causes increased tool wear and thermal damage to tooth flanks
Solution Approach 1:
The patent applies preliminary action by measuring the allowance distribution on tooth flanks before the grinding operation begins. These preliminary measurements provide advance information about the actual material that needs to be removed, allowing the feed rate to be pre-calculated and optimized for each axial position. This prevents both excessive material removal and insufficient grinding, avoiding tool wear and thermal damage.
Solution Approach 2:
The patent implements parameter changes by modifying the feed rate parameter based on measured allowance values. The feed rate is changed as a function of axial position, with higher feed rates where more material needs to be removed and lower feed rates where less material remains. This dynamic parameter adjustment optimizes productivity while preventing harmful effects like tool wear and thermal damage.
3Measurement precision
If measurements are taken at multiple axial positions, then the actual allowance distribution can be accurately determined, but the process complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the tooth flank measurement into multiple axial positions. Instead of measuring the entire tooth flank at once, the measurement system takes discrete measurements at specific axial locations. These segmented measurements are then combined to create a complete picture of the allowance distribution, enabling precise feed rate control without requiring an overly complex measurement system.
Data Source
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AI summary
The invention relates to a method for griding the toothing (1) or the profile of a workpiece (2), in particular a gear wheel, wherein the workpiece (2) has an axis of rotation (a) and wherein an excess (A) is ground away from the surface of the tooth flanks of the toothing (1) or the profile. In order to optimise the grinding process, according to the invention, the method comprises the following steps: a) measuring the position of the surface of the tooth flanks of the toothing (1) or the profile, wherein the measuring is carried out in at least two positions (P1, P2) of the workpiece (2), which are arranged offset in the direction of the axis of rotation (a); b) determining the actually existing excess (A) of the workpiece (2) that has not yet been ground, based on the measurement values determined in step a); c) establishing at least one grinding parameter (v) so that the material removal rate does not exceed a predefined value during grinding; d) grinding the workpiece (2) with the grinding parameters (v) established according to step c).