Gear Tooth Grinding with In-Process Tip Edge Rounding
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Solution Overview
Problem
The production of bevel gears for helicopters requires high precision and tolerance in manufacturing, especially in the tip edge roundings to ensure smooth operation under high torque conditions, while existing methods are inefficient and prone to inaccuracies due to re-clamping and burr formation.
Innovation Solution
A method involving NC-controlled grinding in a processing machine with two separate tool spindles for precise grinding and removal of burrs, allowing for efficient and reproducible production of head edge roundings without re-clamping, using a first grinding tool for tooth flanks and a second tool for tip edge rounding, followed by further grinding to ensure surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single grinding process is used for tooth flanks and tip edge roundings, then the manufacturing process is simpler, but manufacturing precision deteriorates due to the need to re-clamp the workpiece
Solution Approach 1:
The patent combines multiple grinding operations (tooth flank grinding and tip edge rounding) into a single clamping cycle by using multiple grinding tools that can be positioned on different spindles. This allows sequential processing of different gear surfaces without releasing and re-clamping the workpiece, thereby maintaining dimensional accuracy while achieving complex geometries.
Solution Approach 2:
The patent divides the grinding process into distinct segments by assigning different grinding tools to different spindles. Each spindle can be independently controlled to perform specific grinding operations on different portions of the gear, allowing precise control over each processing stage while maintaining continuous clamping.
2Manufacturing precision
If tip edge roundings are ground with a second grinding tool, then head edge rounding precision is improved, but device complexity increases due to requiring two tool spindles
Solution Approach 1:
The patent makes the grinding system multi-functional by equipping different spindles with different grinding tools that can be selectively positioned. The first spindle with its grinding tool handles tooth flank grinding, while the second spindle with its grinding tool handles tip edge rounding. This universal approach allows one machine to perform multiple specialized operations.
3Manufacturing precision
If NC-controlled movements are used for grinding, then manufacturing precision is improved, but use of energy increases
Solution Approach 1:
The patent implements continuous NC-controlled grinding operations where the workpiece remains clamped and multiple grinding tools operate in sequence without interruption. The NC system coordinates the positioning and movement of multiple spindles and tools continuously, eliminating idle time and re-clamping operations, thereby achieving high precision while optimizing energy utilization through uninterrupted productive action.
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 method enables highly precise and efficient production of head edge roundings with reliable removal of burrs, maintaining dimensional stability and surface quality, suitable for high-torque applications like helicopters, and can be applied to various gear types.
Implementation Method 1
grinding processing of at least one tooth flank in the transition area to the tooth tip of the gear workpiece with the second grinding tool
Data Source
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AI summary
Method for grinding and reworking an already toothed gear workpiece (10) in an NC-controlled machine tool (200), comprising the steps: a. providing the gear workpiece (10) in the machine tool (200), b. providing a first grinding tool (206) in the machine tool (200), c. providing a second grinding tool (207) in the machine tool (200), d. grinding at least one tooth flank of the gear workpiece (10) with the first grinding tool (206), e. abrasive machining of at least one tooth flank in the transition area to the tooth head of the gear workpiece (10) with the second grinding tool (207) in order to produce a head edge rounding on the gear workpiece (10), f. further abrasive machining of at least the tooth flank of the gear workpiece (10) with the first grinding tool (206) and/or the second grinding tool (207) in the machine tool (200).