Gear Machining Tool Stepwise Radial Profile for Wear Reduction
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Solution Overview
Problem
Conventional gear machining methods that involve synchronously rotating a machining tool and a work piece to create teeth are limited by short tool life and increased machining time due to excessive wear of protruding tool edges, which are not effectively addressed by existing techniques.
Innovation Solution
A gear machining apparatus with a machining tool featuring protruding tool edges having radial outer faces with multiple steps parallel to the central axis, allowing for a stepwise increase in diameter, enabling the tool to cut a large amount in a single operation without frequent feeding, thus reducing machining time and extending tool life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the machining tool uses conventional protruding tool edges with flat radial outer faces, then the tool can be manufactured simply, but the tool life is significantly reduced due to excessive wear
Solution Approach 1:
The invention applies different geometric characteristics to different parts of the tool edge. Specifically, the radial outer face is designed with a curved surface (circular arc) rather than a flat surface, creating a specific envelope shape that reduces wear. This local geometric modification at the tool edge while maintaining overall tool simplicity resolves the contradiction between ease of manufacture and tool life.
2Manufacturing precision
If the machining tool feeds in the direction of the work piece axis multiple times, then the teeth can be created through roughing and finishing operations, but the machining time is increased
Solution Approach 1:
The invention changes the geometric parameters of the tool edge by designing a curved radial outer face with a specific envelope shape (circular arc). This parameter change allows the tool to maintain cutting effectiveness throughout the entire feeding process, enabling single-pass machining that creates both rough and finished surfaces simultaneously, thereby reducing machining time while maintaining precision.
3Duration of action of moving object
If the protruding tool edges are re-polished after wear, then the tool can be reused, but the accuracy of the tool edges is reduced
Solution Approach 1:
The curved radial outer face design creates a self-maintaining envelope shape that distributes wear more uniformly across the tool edge. This local geometric quality ensures that even after multiple uses and re-polishing operations, the fundamental accuracy and cutting precision of the tool edge are preserved better than with flat-faced tools.
4Device complexity
If the same parts of the protruding tool edges contact the work piece from roughing to finishing, then the tool structure is simplified, but the tool is significantly worn off
Solution Approach 1:
The invention modifies the geometric parameters of the tool edge by implementing a curved radial outer face with a specific envelope shape. This parameter change allows the entire tool edge to effectively participate in cutting throughout the feeding process, distributing the cutting load and reducing wear on any single part, thereby extending tool life without increasing structural complexity.
Data Source
AI summary
A gear machining apparatus includes a machining tool having a plurality of protruding tool edges on an outer periphery of the machining tool, and driving apparatuses that form a tooth on a work piece by rotating the machining tool around a central axis thereof, rotating the work piece W around a central axis thereof, and moving the machining tool relative to the work piece. Radial outer faces of the protruding tool edges form multiple steps that are parallel to the central axis of the machining tool such that the diameter of the machining tool increases in a stepwise manner from a tool leading end toward a tool base end of the machining tool.