Crossed-Axis Gear Peeling with Reverse Axial Feed
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Solution Overview
Problem
Existing hard peeling methods for machining toothed workpieces face challenges in achieving high-quality cuts due to the risk of chip jamming, which impairs the quality of the machined tooth spaces, particularly in processes involving hardened workpieces and complex gear designs.
Innovation Solution
The method involves a feed movement component parallel to the workpiece axis directed opposite to the cutting movement component, effectively changing the tool movement from a pushing to a pulling action, reducing the risk of chip jamming, and allowing for precise control of feed movements to achieve improved surface quality. This can be implemented using a peeling wheel with a conical or cylindrical base, with adjustments in machine axis movements to maintain clearance angles and suitable cutting edge designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a feed movement component parallel to the workpiece axis is used in the same direction as the cutting movement component, then the machining process is simpler to implement, but chip jamming occurs which impairs the quality of the machined tooth spaces
Solution Approach 1:
The patent applies inversion by reversing the direction of the feed movement component parallel to the workpiece axis. Instead of moving in the same direction as the cutting movement component (conventional approach), the feed movement is directed opposite to the cutting movement component. This causes the tool to perform a pulling action rather than a pushing action, which prevents chip jamming in the machined tooth spaces and improves surface quality.
2Productivity
If the peeling wheel is subjected to high cutting forces, then material removal is more efficient, but the stress on the peeling wheel increases which may affect tool life and precision
Solution Approach 1:
The patent reverses the conventional pushing action to a pulling action by directing the feed movement component opposite to the cutting movement component. This pulling action reduces the stress forces acting on the peeling wheel during machining, allowing for more sustainable tool operation and extended tool life while maintaining material removal efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the quality of machined surfaces by reducing chip jamming and allows for the production of high-quality straight and helical gears, both internal and external, with reduced stress on the peeling wheel, enabling more precise control over the machining process.
Implementation Method 1
The peeling wheel is brought into rolling contact with the workpiece at a crossed axis angle between the two axes of rotation
Data Source
Figure 1~2b
Figure 3~4b
AI summary
The invention relates to a method for machining a workpiece which is driven in rotation about a workpiece axis and is in the form of a periodic structure, in particular a toothed workpiece, wherein a toothed machining tool which is provided with a cutting edge formed on an end edge of its teeth and is driven in rotation about a tool axis that is spaced apart from the workpiece axis in the radial direction of the axis spacing is brought into rolling engagement with the workpiece at a crossed-axes angle between the two rotational axes, wherein the cutting edge removes material from the workpiece in a cutting movement that has a component parallel to the axis of the workpiece, and the machining tool is additionally made to execute a feed movement having a component parallel to the axis of the workpiece in order to machine the workpiece over a desired axial extent, wherein the components, parallel to the axis of the workpiece, of the feed movement and the cutting movement are directed in opposite directions to one another.