Gear Skiving Tool Axis Cross Angle Adjustment
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Solution Overview
Problem
The existing skiving methods face challenges in achieving optimal surface quality of tooth flanks and preventing uneven wear on skiving tools, particularly due to varying chip formation conditions at different cutting depths, which affect tool life and manufacturing costs.
Innovation Solution
A skiving method with a multi-cut strategy that involves gradually adjusting the effective axis cross angle to improve chip formation conditions, using a skiving tool optimized for the final cut and adjusting the axis cross angle step-by-step for preceding cuts to maintain consistent cutting conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a constant axis cross angle is used throughout the skiving process, then the machining process is simple to control, but uneven wear occurs on the skiving tool and surface quality deteriorates
Solution Approach 1:
The patent applies dynamics by transitioning from a static axis cross angle to a dynamic one that changes during the skiving process. The axis cross angle is adjusted based on the current cutting depth, allowing the system to adapt to varying chip formation conditions at different stages of material removal, thereby preventing uneven tool wear and improving surface quality.
Solution Approach 2:
The patent implements parameter changes by modifying the axis cross angle as a variable parameter throughout the skiving process. Instead of maintaining a constant angle, the system varies the axis cross angle according to the current cutting depth, optimizing chip formation conditions at each stage and resolving the contradiction between operational simplicity and manufacturing precision.
2Device complexity
If the skiving tool is optimized for final cut only, then the tool design is simplified, but chip formation conditions are suboptimal during preliminary cuts
Solution Approach 1:
The patent applies dynamics by making the axis cross angle a dynamic parameter that adapts to different cutting stages. This allows a single tool design to optimize chip formation for both preliminary and final cuts by adjusting the angle during operation, rather than requiring different tools or maintaining a constant suboptimal angle.
Solution Approach 2:
The patent implements parameter changes by varying the axis cross angle according to cutting depth. This enables the same tool to achieve optimal chip formation conditions throughout the entire skiving process, from preliminary to final cuts, without increasing tool design complexity.
3Manufacturing precision
If multiple different axis cross angles are used for different cutting depths, then chip formation conditions improve, but the control system becomes more complex
Solution Approach 1:
The patent applies dynamics by implementing a dynamic axis cross angle control system that automatically adjusts the angle based on real-time cutting depth information. This dynamic adaptation improves chip formation quality while the control system manages the complexity through automated parameter adjustment based on process stage.
Solution Approach 2:
The patent implements parameter changes by systematically varying the axis cross angle as a function of cutting depth. The control system manages this complexity through programmed parameter adjustment, optimizing chip formation at each stage while maintaining automated control.
4Productivity
If a single cut strategy is used, then the machining process is faster, but tool wear increases and service life decreases
Solution Approach 1:
The patent applies segmentation by dividing the skiving process into multiple cutting stages (preliminary cuts and final cut) with different axis cross angles. This segmentation allows optimization of chip formation for each stage, reducing overall tool wear while maintaining efficient material removal through appropriate angle selection at each phase.
Solution Approach 2:
The patent applies dynamics by transitioning from a static single-cut approach to a dynamic multi-stage process where the axis cross angle changes according to cutting depth. This dynamic adaptation enables sustained productivity by preventing excessive tool wear through optimized chip formation conditions at each stage.
Data Source
Figure 1
Figure 2A~2B
Figure 3A
AI summary
This is a method for gear skiving a workpiece (50) with a workpiece rotation axis (R2) and with a rotationally symmetric, periodic structure using a gear skiving tool (100), comprising the following steps: - providing the workpiece (50), - providing the gear skiving tool (100) which has several cutting teeth (111) or cutting inserts, - specifying a first effective axis cross angle Σeff1 of the gear skiving tool (100) with respect to the workpiece (50), - performing a first gear skiving operation on the workpiece (50) with the specified first effective axis cross angle Σeff1, wherein during the first gear skiving operation the gear skiving tool (100) penetrates the workpiece (50) to a first infeed depth and skims the flanks (53, 54) of the periodic structure of the workpiece (50). pre-machined, ▪ specifying a second effective axis cross angle Σeff2 of the gear skiving tool (100) in relation to the workpiece (50),▪ Performing a second skiving operation on the workpiece (50) with the specified second effective axis cross angle Σeff2, wherein during the second skiving operation the skiving tool (100) penetrates the workpiece (50) to a final infeed depth and the flanks (53, 54) of the periodic structure of the workpiece (50) are further machined, and wherein the first effective axis cross angle Σeff1 differs from the second effective axis cross angle Σeff2.