Gear Tooth Grinding With In-Process Wear Feedback
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Solution Overview
Problem
The existing grinding processes for workpieces with toothing or profiles lack efficient monitoring of tool wear and oversize removal, leading to suboptimal machining efficiency and premature tool wear, as they cannot account for current tool wear and oversize during the combined roughing and finishing processes.
Innovation Solution
Implementing a method that uses dressable grinding wheels or worms for both roughing and finishing, with real-time measurement of geometric parameters during roughing to determine tool wear and initiate dressing processes based on specified limits, allowing for adaptive control and optimal tool utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a fixed roughing process is used for the entire batch of workpieces, then the process is simple to maintain, but the actual stock allowance and tool wear cannot be accounted for, leading to premature tool wear and reduced efficiency
Solution Approach 1:
The patent implements in-process measurement of the workpiece toothing geometry during rough grinding, with the measured values fed back to the machine control system. This feedback enables dynamic adjustment of the roughing process parameters based on actual stock allowance and tool wear conditions, optimizing productivity while managing process complexity through automated control
Solution Approach 2:
The patent performs measurement of the workpiece geometry during the roughing process itself, before the finishing process begins. This preliminary measurement provides information about actual stock allowance and tool wear that can be used to adjust subsequent finishing operations, preventing premature tool wear and improving overall machining efficiency
2Duration of action of moving object
If the roughing tool is used until significant wear occurs, then tool life is extended, but the finishing tool is subjected to greater stress and wear
Solution Approach 1:
The patent uses in-process measurement during roughing to provide feedback on tool wear and stock removal. This feedback enables determination of the optimal time for dressing or changing the roughing tool, ensuring it is renewed before excessive wear occurs that would compromise the finishing process, thus balancing tool life extension with finishing process reliability
Solution Approach 2:
The patent determines the optimal tool renewal time during the roughing process itself, before the tool wears excessively. This preliminary determination of tool wear status allows for timely dressing or replacement, preventing negative impacts on the subsequent finishing process while maximizing roughing tool utilization
3Loss of information
If measurement is performed after roughing and finishing, then the process is simple, but real-time tool wear monitoring and adaptive control are not possible
Solution Approach 1:
The patent implements measurement of the workpiece toothing geometry during the roughing process, with real-time feedback to the machine control system. This enables continuous monitoring of tool wear and stock removal, providing real-time process information that can be used for adaptive control of both roughing and finishing operations, while the integrated measurement system manages complexity through automation
Solution Approach 2:
The patent combines the measurement function with the existing grinding machine system, integrating sensors and evaluation units into the machine control. This merging of measurement and machining functions enables real-time tool wear monitoring and adaptive control without requiring completely separate measurement equipment, thus managing device complexity while gaining real-time process information
Data Source
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AI summary
The invention relates to a method for grinding a workpiece (1) with a toothing (2) or a profile, in which, in a single workpiece clamping operation in the grinding machine, the toothing (2) or the profile is pre-machined using a rough-grinding tool (6) in a first step and then the toothing (2) or the profile is finished using a smooth-grinding tool in a second step. In order to make the machining more efficient and in particular to define the optimal point in time for a new dressing process, the invention provides that simultaneously with the first working step the toothing (2) or the profile is measured by means of at least one sensor (3, 4, 5), wherein a geometric variable defining the toothing (2) or the profile or a variable linked to the geometry is measured, and wherein the deviation of the measured geometric variable or of the variable linked to the geometry is determined from a target value in the machine control.