Gear Shaping Tool Path for Collision-Free Helical Toothing
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Solution Overview
Problem
Existing gear shaping methods face challenges in maintaining a collision-free tool path, particularly when machining helical gears, due to the risk of interference between the tool and workpiece, which can lead to collisions during the return stroke.
Innovation Solution
The method involves superimposing an evasive movement of the tool away from the incoming flank of the workpiece, transverse to the lifting direction, during the return stroke, achieved through additional rotation of the tool, which reduces the risk of collision by shifting the disturbing approach to higher return stroke levels and minimizing the lifting amount required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tool is lifted off the workpiece during the return stroke to avoid collision, then collision risk is reduced, but the lifting amount increases and vibrations are amplified
Solution Approach 1:
The patent introduces an evasive movement in a direction transverse to both the lifting direction and the stroke direction, creating a three-dimensional tool path modification. This additional dimensional movement allows the tool to clear the incoming flank of the workpiece during the return stroke without requiring excessive lifting in the radial direction, thereby reducing the lifting amount while maintaining collision avoidance
Solution Approach 2:
The patent implements dynamic control of the tool path by superimposing the evasive movement on the conventional lifting motion. The evasive movement is activated specifically during the return stroke when the tool is in the lifted state, creating a dynamic, conditional tool path adjustment that adapts to the machining phase and minimizes unnecessary tool displacement
2Reliability
If the tool is lifted higher to ensure collision-free return stroke, then reliability improves, but manufacturing precision deteriorates due to increased vibrations
Solution Approach 1:
By adding the transverse evasive movement component, the patent achieves collision avoidance with reduced radial lifting, thereby minimizing vibration excitation and maintaining manufacturing precision. The evasive movement provides the necessary clearance from the incoming flank without the excessive radial displacement that would amplify vibrations and degrade precision
3Reliability
If additional machine axes are provided to achieve evasive movement, then collision avoidance improves, but device complexity increases
Solution Approach 1:
The patent merges the evasive movement function with the existing tool lifting mechanism by controlling the tool's rotational position. Instead of adding a separate mechanical axis for evasive movement, the invention combines the lifting motion and evasive motion through coordinated control of the tool's angular position during the return stroke, thereby achieving collision avoidance without increasing device complexity
Solution Approach 2:
The patent replaces potential mechanical complexity with electronic control by implementing the evasive movement through electronic control of the tool's rotational position. The evasive movement is achieved by electronically adjusting the tool's angular orientation during the return stroke rather than through additional mechanical axes, reducing device complexity while maintaining collision avoidance capability
Data Source
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Figure 3
Figure 4a~4c
AI summary
The invention relates to a method for gear shaping a periodic structure, in particular a toothing on a workpiece, in which method the workpiece, continuously rotating about its axis of rotation, is brought into material-removing machining engagement with a toothed shaping tool which rotates about its axis of rotation in rolling contact with the workpiece rotation. After a working stroke, the shaping tool is lifted off from the workpiece in a lifting direction and, after a subsequent return stroke, the shaping tool in the lifted state is returned to the workpiece again for the next working stroke. In the return stroke, a deflection movement of the shaping tool away from the incoming flank of the workpiece and transversely to the lifting direction is superimposed on the rolling contact.