Gear Hobbing with Integrated Secondary Deburring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing gears are time-consuming and expensive due to the need for multiple clamping and synchronization steps in deburring and chamfering processes, which also require specialized tools and additional processing times.
Innovation Solution
A method that uses a rotary holder with two workpiece spindles to pivot between machining and transfer positions, allowing for pre-milling, chamfering, cutting, and fine milling in a single clamping setup, eliminating the need for separate deburring machines and specialized tools, and optimizing tool utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional deburring and chamfering methods are used with multiple clamping and synchronization steps, then deburring quality can be achieved, but production time and costs increase significantly
Solution Approach 1:
The patent combines multiple operations (milling, deburring, chamfering) into a single integrated machining process. The hobbing cutter performs both tooth generation and edge deburring/chamfering in one clamping operation, eliminating the need for separate deburring machines and multiple workpiece repositionings. This merging of operations directly resolves the contradiction by maintaining deburring quality while dramatically reducing production time.
Solution Approach 2:
The deburring and chamfering edges are prepared in advance during the hobbing process itself, before the workpiece is removed for final inspection or assembly. The cutter edges are shaped to perform deburring and chamfering functions as part of the primary machining operation, so that when the workpiece is completed, the edges are already properly prepared without requiring additional operations.
2Manufacturing precision
If specialized deburring tools and separate machines are used, then deburring effectiveness is improved, but device complexity and costs increase
Solution Approach 1:
The hobbing cutter is designed to perform multiple functions: generating gear teeth, deburring tooth edges, and chamfering edges. This multi-functional tool eliminates the need for specialized deburring machines and tools, reducing device complexity while maintaining deburring effectiveness. The same cutter that creates the teeth also prepares the edges, making the system more versatile and less complex.
Solution Approach 2:
The patent merges the functions of tooth generation and edge preparation into a single machining operation using one cutter. This consolidation eliminates the need for separate deburring equipment, thereby reducing device complexity while maintaining the effectiveness of edge preparation through the integrated design of the hobbing process.
3Manufacturing precision
If multiple separate machining operations are performed, then each operation can be optimized, but total assembly time and synchronization requirements increase
Solution Approach 1:
The patent combines multiple machining operations (milling, deburring, chamfering) into a single synchronized hobbing operation. The cutter performs all these functions simultaneously during one continuous machining process, eliminating the need for separate operations, multiple clamping steps, and complex synchronization between different machines. This directly reduces assembly time while maintaining the precision benefits of optimized machining.
Solution Approach 2:
The hobbing process continues uninterrupted to perform tooth generation, deburring, and chamfering in a single continuous operation. The cutter moves continuously through the workpiece, performing all necessary operations without stopping for repositioning or tool changes. This continuous action eliminates idle time and synchronization delays between separate operations, reducing total assembly time while maintaining optimization benefits.
Data Source
Figure 1
Figure 2a)~2d)
Figure 3a~4c
AI summary
The invention relates to a method for working the toothing of workpieces (3), in particular gear wheels, comprising milling, deburring by hobbing and integrated secondary deburring. The method is performed on a machine tool (1) with two workpiece spindles (11, 12), which can change places with each other. A workpiece (3) is mounted on a first workpiece spindle (11), followed by the workpiece spindles (11, 12) changing place with each other, followed by pre-milling and possibly cutting (= deburring by stripping) of the workpiece (3), followed by a further change of place, followed by chamfering and cutting of the workpiece (3), followed by a further change of place, followed by finish-milling of the workpiece (3), followed by a further change of place, followed by a change of workpiece. At the same time, the same sequence is performed on the second workpiece spindle (12), at a time deferred by a change of place of the workpiece spindles (11, 12). With the method according to the invention, well-deburred toothed workpieces (3) can be produced quickly and at low cost.