Gear Tooth Shaving with Two-Step Load Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing shaving processing methods for gears face high processing loads, leading to increased transmission errors and vibrations due to the need for a single, large cut in one-time processing, which can result in noise and accuracy issues.
Innovation Solution
A method and apparatus that divide the shaving process into two steps with gradually expanding processing regions, using an intersection angle adjustment mechanism to set different angles for each step, reducing the overall processing load and minimizing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large cut amount is processed in one-time shaving, then productivity is improved, but manufacturing precision deteriorates due to increased processing load causing errors
Solution Approach 1:
The shaving process is divided into multiple passes with different cut amounts. The first pass uses a larger cut amount for efficient material removal, while the second pass uses a smaller cut amount for precise finishing. This segmentation allows the system to achieve both high productivity in the first pass and high precision in the second pass, resolving the contradiction between productivity and manufacturing precision.
2Productivity
If a large cut amount is processed in one-time shaving, then productivity is improved, but reliability deteriorates due to increased processing load causing vibration and noise
Solution Approach 1:
By dividing the shaving process into multiple passes, the processing load in each pass is reduced compared to a single large cut. This segmentation prevents excessive vibration and noise that would occur with large single-pass cuts, thereby maintaining transmission reliability while still achieving high overall productivity through optimized multi-pass processing.
Solution Approach 2:
The first shaving pass removes a larger portion of material than would be removed in a single precision pass, accepting some reduced precision in exchange for higher productivity. The second pass then performs the precise finishing work. This partial action approach allows the system to achieve both high productivity and high reliability by distributing the cutting load across multiple specialized passes.
Data Source
AI summary
A shaving processing method and apparatus for a gear are provided which reduce a load at the time of processing a tooth surface, thereby reducing a transmission error of the gear. Embodiments include a method for finishing the tooth surface of the gear in a state where the gear and a shaving cutter are engaged with each other and the shaving cutter is rotated. The gear has a pair of end surfaces facing each other in the tooth width direction. A first shaving step of processing the tooth surface is performed so that a processing region gradually expands from one end surface of the pair of end surfaces toward the other end surface, and a second shaving step of processing the tooth surface is performed so that a processing region gradually expands from the other end surface of the pair of end surfaces toward the one end surface.