Gear Skiving Chamfering for Precise Toothed Workpiece Wheels
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Solution Overview
Problem
Existing methods for producing toothed workpieces with chamfers between the tooth root and end face are inefficient, as they lack precise control over the chamfer angle and symmetry of tooth flanks, leading to suboptimal machining results.
Innovation Solution
A method using a gear-cutting tool and a chamfer tool, both skiving wheels with cutting teeth forming cutting edges, where the axis of rotation of each tool is at a crossed-axes angle to the workpiece wheel, allowing synchronous rotational movement and controlled infeed to create precise toothing and chamfers, with the chamfer tool having a profile correction to ensure asymmetrical cutting edges for accurate chamfer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a skiving wheel with cutting edges is used to produce toothing, then the toothing can be created efficiently, but the chamfer formation between tooth root and end face cannot be achieved with precise control
Solution Approach 1:
The cutting wheel is divided into multiple cutting teeth (first number of cutting teeth) distributed around the circumference, with each tooth having cutting edges that form during rotation. This segmentation allows the wheel to create multiple tooth gaps simultaneously while maintaining precise chamfer angles through the geometric relationship between cutting tooth inclination and wheel rotation
Solution Approach 2:
The cutting edges are formed in the transition area of the tooth flanks to an end face of the cutting tooth, utilizing the third dimension (depth/axial direction) to create the chamfer geometry. The end faces of cutting teeth can be located in a shared plane or arranged offset in a step-like manner, providing dimensional control over chamfer formation
2Manufacturing precision
If the axis of rotation of the gear-cutting tool is at a crossed-axes angle to the workpiece wheel, then synchronous rotational movement enables precise toothing, but the device requires complex adjusting aggregates
Solution Approach 1:
The crossed-axes angle between the gear-cutting tool axis and workpiece wheel axis is optimized to enable synchronous rotational movement. This parameter change allows the cutting teeth to engage the workpiece at precise angles, creating symmetrical tooth flanks through the geometric relationship between rotation speed ratio and crossed-axes angle
Solution Approach 2:
The workpiece wheel and gear-cutting tool are driven synchronously with a defined speed ratio, creating a feedback mechanism where the rotation of one wheel automatically controls the cutting action of the other. This synchronous coupling ensures consistent chamfer angles and tooth flank symmetry without requiring complex real-time adjustments
3Manufacturing precision
If multiple consecutive steps are used to produce toothing with gradual axial distance changes, then finishing precision is improved, but the production time increases
Solution Approach 1:
The cutting teeth are designed with predetermined geometry including inclined tooth flanks and end faces at specific angles. This preliminary action of pre-configuring the cutting tool geometry allows the chamfer and tooth flanks to be formed with the desired precision in fewer passes, reducing the number of consecutive machining steps required
Solution Approach 2:
The skiving process creates continuous cutting action as the gear-cutting tool rotates synchronously with the workpiece wheel. The cutting edges continuously engage and remove material in a smooth, uninterrupted manner, maintaining high surface finish quality while maximizing material removal efficiency and reducing total machining time
Data Source
AI summary
A method for producing a toothed workpiece wheel, the tooth root of which adjoins an end face of the workpiece wheel with a chamfer extending into the tooth flanks being formed, wherein the toothing of the workpiece wheel is created by skiving with a gear-cutting tool which has a first number of cutting teeth that each form cutting edges and the rotation axis of which is at a first crossed-axes angle to the axis of rotation of the workpiece wheel, with an infeed in a first infeed direction parallel to the direction of extension of the tooth flanks to be produced and of the tooth root. The chamfer is created by skiving with a chamfering tool which has a second number of cutting teeth that each form cutting edges and the rotation axis of which is at a second crossed-axes angle to the axis of the workpiece wheel, with an infeed in a second infeed direction parallel to the direction of extension of the chamfer to be produced in the tooth root. Also disclosed is an associated tool set.