Gear Shaping Setpoint Correction for Tooth Profile Accuracy
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Solution Overview
Problem
Existing gear machining methods face challenges in achieving high processing precision while minimizing processing time, as profile shape deviations occur due to process forces during machining, despite control efforts to maintain target values.
Innovation Solution
A method that corrects the setpoints of NC-controlled machine axes by accounting for tooth flank displacements caused by process forces, using a harmonic setpoint correction function and phase offset to minimize profile shape deviations, allowing for reduced adjustments to technology parameters and processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If process forces are applied during gear machining to achieve material removal, then productivity is improved, but profile shape deviations increase due to tooth flank displacement
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing correction values for setpoint positions before machining begins. These correction values are determined based on the specific process design and are loaded into the control system in advance, allowing the control system to proactively compensate for expected tooth flank displacements during machining without requiring real-time measurements or adjustments
Solution Approach 2:
The patent implements parameter changes by modifying the setpoint position values that are fed to the control system. Instead of using the original target positions, the system uses corrected setpoint positions that account for anticipated tooth flank displacements. This changes the control parameters dynamically based on the process design, allowing the machining system to maintain accuracy despite the application of process forces
2Manufacturing precision
If the number of shaping strokes per pitch is increased to reduce profile shape deviations, then manufacturing precision is improved, but processing time increases
Solution Approach 1:
The patent applies parameter changes by modifying the setpoint position parameters to compensate for tooth flank displacements. This allows achieving improved profile shape accuracy without needing to increase the number of shaping strokes, as the correction is applied through parameter adjustment rather than through additional machining passes
3Manufacturing precision
If technology parameters and process design are adjusted to reduce profile shape deviations, then manufacturing precision is improved, but device complexity and setup time increase
Solution Approach 1:
The patent implements self-service by enabling the control system to automatically apply corrections based on pre-stored correction values. The system serves itself by having the control system autonomously adjust setpoint positions using the loaded correction values, without requiring manual intervention or complex external adjustment mechanisms
Solution Approach 2:
The patent applies preliminary action by pre-calculating and storing correction values before machining begins. This eliminates the need for complex real-time adjustments or modifications to the underlying process design, as all necessary corrections are prepared in advance and automatically applied during machining
Data Source
Figure 1a~1b
Figure 2
AI summary
The invention relates to a method for creating or machining toothings on workpieces in rolling machining engagement, in particular by gear shaping, in which NC control of the rotary spindle drives of workpiece and tool comprises regulation of the rotation angle position of each particular spindle to setpoints determined depending on the process parameters associated with the process design underlying the method, wherein data containing information relating to a deflection, caused by the process forces that arise during machining and resulting in profile shape deviations on the workpiece, of the position of the tool flanks of tool and workpiece out of their position intended as per the process design, are used to determine a correction, taking the deflection into account, of the rotation angle position of the workpiece spindle and/or tool spindle and thus to modify the setpoints of the regulation.