Gear Honing Tool Dressing for Tooth Flank Twist Modification
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Solution Overview
Problem
Existing methods for producing flank modifications, such as twists, on gear wheels require complex control systems and additional axes for precise adjustments, which is not feasible with machine tools having a reduced number of adjustable axes.
Innovation Solution
A method that uses a narrow internally-toothed dressing tool with a width smaller than the externally-toothed honing tool, where the axis cross-angle is set before dressing and maintained unchanged, allowing modifications to be introduced by movements along the workpiece longitudinal and transverse axes, reducing the need for additional axis adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a narrow dressing wheel is used to produce flank modifications, then the complexity of control systems and additional axes is reduced, but the manufacturing precision and ability to introduce complex twists is limited
Solution Approach 1:
The patent applies dimensionality change by utilizing the axis cross angle (skew angle) between the dressing wheel rotational axis and the tool rotational axis as an additional degree of freedom. Instead of requiring multiple adjustment axes on the dressing device, the method introduces the modification in the angular dimension by setting a specific axis cross angle ΣA, which enables complex twist profiles to be generated with fewer mechanical axes while maintaining manufacturing precision.
Solution Approach 2:
The patent employs parameter changes by varying the axis cross angle ΣA and the rotational speeds of the dressing wheel and tool during the dressing process. By dynamically adjusting these parameters, the method can introduce different types and magnitudes of flank modifications (including twists) without requiring additional mechanical axes, thus resolving the contradiction between device complexity and manufacturing precision.
2Adaptability or versatility
If the axis cross angle is adjusted continuously during dressing, then the flexibility to produce different flank modifications is improved, but the device complexity and number of required actuators increases
Solution Approach 1:
The patent applies preliminary action by pre-setting the axis cross angle ΣA to a specific value before the dressing process begins. This predetermined angular setting enables the dressing wheel to generate the desired twist profile on the tool flanks without requiring continuous adjustment during operation. The flexibility to produce different modifications is achieved by changing the pre-set angle between dressings rather than during the dressing process, thereby reducing the number of actuators needed.
Solution Approach 2:
The patent implements universality by using a single actuator system that controls the axis cross angle setting, which then enables the production of various types of flank modifications (different twist profiles, crown modifications, etc.) through software control and parameter variation. This multi-functional approach allows one mechanical system to perform multiple dressing operations without requiring dedicated actuators for each modification type.
Data Source
AI summary
The invention discloses a method for producing modifications, such as twists, on the tooth flanks of an internally-toothed workpiece by an externally-toothed tool. In order to carry out such a method also with machine tools, which have a reduced number of adjustable axes, the invention provides that the tool is dressed by arranging an internally-toothed dressing tool on the workpiece spindle of the machine tool at the position intended for the workpiece to be respectively honed and by bringing the dressing tool into engagement with the tool to be dressed. The width of the teeth of the dressing tool is smaller than the width of the tool to be dressed such that the dressing tool must be moved by a length along the workpiece longitudinal axis which corresponds to a multiple of the width of the teeth of the dressing tool. Subsequently, the fine machining of the workpiece takes place with the tool dressed in this manner. According to the invention, an axis cross angle is set for the dressing, which is maintained unchanged during the dressing. The respective tooth flank modification is then produced during dressing exclusively by movements of the dressing tool along the workpiece longitudinal axis and the workpiece transverse axis.