Variable-Speed Gear Machining to Suppress Chattering Vibration
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Solution Overview
Problem
Gear machining processes face challenges with chattering vibrations when increasing rotation speed or cutting amount, leading to reduced machining efficiency and surface quality.
Innovation Solution
A gear machining apparatus and method that synchronizes and varies the rotation speeds of the workpiece and gear cutting tool along the workpiece's rotation axis, creating an irregular contact cycle to suppress chattering vibrations while maintaining high cutting efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rotation speed of the gear cutting tool is increased or the cutting amount is increased, then machining efficiency is improved, but chattering vibration occurs in the workpiece
Solution Approach 1:
The invention applies dynamics by making the rotation speeds of the gear cutting tool and workpiece variable rather than constant. The control device varies the rotation speeds during the machining process, creating irregular contact cycles between the tool and workpiece that prevent chattering vibration while maintaining high cutting amounts for improved machining efficiency
Solution Approach 2:
The invention changes the rotational speed parameters of both the gear cutting tool and workpiece from fixed values to variable values. By continuously adjusting these parameters during machining, the system prevents the periodic contact that causes chattering vibration, allowing larger cutting amounts to be used without generating harmful vibrations
2Manufacturing precision
If the cutting amount is reduced to suppress chattering vibration, then surface features are improved, but machining time is increased
Solution Approach 1:
The system uses dynamic variation of rotation speeds to achieve both high surface quality and efficient machining. By varying the speeds, the invention allows larger cutting amounts to be used without degrading surface features, thus reducing machining time while maintaining manufacturing precision
Solution Approach 2:
By changing the rotational speed parameters during machining, the invention enables the use of larger cutting amounts that reduce machining time while still achieving good surface features through the irregular contact cycles that prevent chattering vibration
Data Source
AI summary
A gear machining apparatus creates a gear on a workpiece W by moving a gear cutting tool relatively with respect to the workpiece along the direction of the rotation axis of the workpiece W while synchronously rotating the gear cutting tool and the workpiece. One of a workpiece rotation speed controlling portion and a tool rotation speed controlling portion varies the rotation speed of one of the workpiece and the gear cutting tool and the other one of the workpiece rotation speed controlling portion and the tool rotation speed controlling portion synchronizes the rotation speed of the other one of the workpiece and the gear cutting tool with one of the rotation speed of the workpiece and the gear cutting tool.