Gear Skiving Tool with Axial Edge Offsets for Quieter Tooth Flanks
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Solution Overview
Problem
Conventional gear skiving processes produce gears with equally spaced feed marks, leading to uniform excitation and noise generation when rolling with a counter gear.
Innovation Solution
A gear skiving tool with cutting edges arranged at different axial heights along the tool axis, ensuring that at least two cutting edges for machining the same tooth flank are offset by a specific distance, typically between 5 µm and 0.5 mm, to vary the temporal and spatial intervals of cutting edge engagements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If cutting edges are arranged at the same height along the tool axis, then the machining process is simple and consistent, but feed marks are equally spaced causing uniform excitation and noise
Solution Approach 1:
The patent applies asymmetry by arranging cutting edges at different axial heights along the tool axis instead of at uniform positions. This asymmetric arrangement causes the cutting edges to engage the workpiece at different temporal and spatial intervals, creating non-uniform feed mark spacing that prevents uniform excitation and reduces noise generation during gear operation
Solution Approach 2:
The patent introduces axial height variation as an additional dimension for cutting edge positioning. By distributing cutting edges along the axial direction rather than only in the radial or circumferential directions, the invention creates varied engagement sequences that broaden the frequency spectrum and reduce noise
2Object-generated harmful factors
If cutting edges are arranged at different axial heights, then feed marks are non-equidistant reducing noise, but the tool design and manufacturing become more complex
Solution Approach 1:
The patent applies local quality by giving each cutting edge a specific axial height position tailored to its function. Different cutting edges are positioned at different axial heights to create varied engagement patterns, with each local position optimized to contribute to non-uniform feed mark spacing and noise reduction
3Productivity
If multiple cutting edges engage the same tooth flank, then material removal is efficient, but vibrations and noise occur due to discrete cutting edge engagements
Solution Approach 1:
The patent applies periodic action through the sequential engagement of multiple cutting edges arranged at different axial heights. The cutting edges engage the tooth flank in a periodic sequence with varying intervals, creating a distributed engagement pattern that maintains continuous material removal while broadening the frequency spectrum to reduce vibrations and noise
Data Source
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AI summary
The invention relates to a gear skiving tool (74) and the machining of gears by gear skiving, whereby machining marks with unequal spacing are produced. For this purpose, at least some cutting edges (40) of the gear skiving tool extend at least partially at different heights (62) along a tool axis (18) of the gear skiving tool. During machining, cutting edges arranged at different axial heights with respect to the workpiece axis engage a tooth flank successively. The engagement of the cutting edges thus occurs at different time intervals and at different intervals in the width direction of the tooth flank. The effects of the cutting edge engagement on the machining process and the excitation of vibrations in the use of the manufactured gear therefore have a frequency spectrum of greater width and lower amplitude than would be the case with temporally and spatially equidistant cutting edge engagements.In particular, the more irregular surface structure of the manufactured gearing can have a positive effect on the noise excitation behavior when the gearing engages with a mating gear.