Gear Shaping Return Stroke Deflection for Collision-Free Toothing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing gear shaping methods face challenges in achieving a collision-free tool path, particularly for internal toothings and workpieces with shoulders, due to the risk of collisions during the return stroke, which can lead to vibrations and require excessive lifting amounts.
Innovation Solution
A deflection movement of the shaping tool, transverse to the lifting direction, is superimposed on the return stroke, utilizing an additional rotation of the tool to minimize the risk of collision by shifting the disruptive approach to higher return stroke levels and reducing the lifting amount, thereby optimizing the tool path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the shaping tool is lifted off completely during the return stroke to avoid collisions, then collision-free operation is achieved, but the lifting amount becomes excessive and cycle time increases
Solution Approach 1:
The patent introduces a deflection movement transverse to the lifting direction, adding a lateral dimension to the tool path. This allows the tool to clear the incoming flank by moving sideways rather than purely upward, reducing the required lifting amount while maintaining collision-free operation during the return stroke
2Reliability
If the shaping tool is lifted with sufficient radial distance to avoid collisions, then collision risk is reduced, but machine vibrations increase due to excessive lifting
Solution Approach 1:
By adding a deflection movement transverse to the lifting direction, the tool achieves collision avoidance with reduced lifting amplitude. This smaller lifting movement generates fewer vibrations while the lateral deflection ensures the tool clears the incoming flank path, thus reducing both collision risk and harmful vibrations simultaneously
3Productivity
If the return stroke takes place with minimal lifting, then cycle time is reduced, but collisions occur with the incoming flank of the workpiece
Solution Approach 1:
The patent superimposes a deflection movement transverse to the lifting direction on the return stroke. This lateral movement component allows the tool to clear the incoming flank with minimal lifting, achieving both short cycle time through reduced lifting and reliable collision avoidance through the transverse deflection path
Solution Approach 2:
The deflection movement is applied in advance during the return stroke to position the tool laterally before the critical transition region is reached. This preliminary lateral positioning ensures that when the tool approaches the workpiece after lifting, it follows a safe path that clears the incoming flank, preventing collisions while maintaining efficient cycle timing
Data Source
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.