Gear Skiving with Replaceable Blades for Lower Machining Cost
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Solution Overview
Problem
High-cost gear machining due to expensive dedicated tool blades and increased replacement frequency in skiving processes, where tool blades need to be specially manufactured for involute tooth shapes, leading to elevated machining costs.
Innovation Solution
A gear machining apparatus and method utilizing replaceable tool blades of simple shapes, not based on the finished gear tooth surface, for both rough and finish machining, allowing for reduced tool blade costs and elimination of full tool replacement expenses, with a system comprising a rough working tool, a finish working tool, a tool spindle, a workpiece spindle, a tool magazine, and a tool changer for efficient blade replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dedicated tool blades formed in involute shape are used for skiving machining, then the gear tooth can be machined with correct tooth profile, but the manufacture of the dedicated tool blade becomes difficult and machining cost increases
Solution Approach 1:
The gear tooth machining process is segmented into two distinct stages: rough machining and finish machining. Different tool blade types are used for each stage - simple-shaped blades for rough machining and dedicated involute-shaped blades for finish machining. This segmentation allows the complex dedicated blades to be used only when necessary for final precision, while the majority of material removal uses simpler, easier-to-manufacture blades.
Solution Approach 2:
The dedicated involute-shaped tool blades are used only for the finish machining portion, not for the entire machining process. The rough machining phase uses simple-shaped blades, and only the final precision-forming stage requires the complex dedicated blades. This partial application reduces the overall frequency of blade replacement and manufacturing costs.
2Strength
If the gear cutting tool is made of solid high-speed tool steel, then the tool has sufficient strength and durability, but the tool replacement cost becomes very high
Solution Approach 1:
The gear cutting tool is segmented into a reusable solid high-speed tool steel body and replaceable tool blade components. The expensive solid tool steel structure is retained for strength and durability, while only the consumable blade portions are replaced when worn. This allows the investment in high-quality material to be preserved and reused across multiple blade sets.
Solution Approach 2:
The consumable cutting edge portion (tool blade) is extracted as a separate replaceable component from the solid high-speed tool steel body. This extraction allows the expensive solid tool steel structure to be preserved and reused, while only the relatively inexpensive blade portions need replacement, significantly reducing replacement costs.
3Manufacturing precision
If tool blades are replaced when wear exceeds limit, then machining quality is maintained, but machining cost increases due to frequent replacement
Solution Approach 1:
The tool blade system is segmented into rough machining blades and finish machining blades with different service lives and cost structures. The simple-shaped rough machining blades can be used until significant wear occurs, while the dedicated finish machining blades are replaced only when necessary to maintain tooth profile precision. This segmentation optimizes the replacement schedule to balance quality requirements with cost efficiency.
4Device complexity
If only one end side of the dedicated tool blade is capable of machining, then the blade shape can be simplified, but the number of times of replacement increases
Solution Approach 1:
The tool blade system is segmented into rough machining blades (simple shape, high replacement frequency) and finish machining blades (dedicated involute shape, lower replacement frequency). The simple-shaped rough machining blades are replaced frequently but are inexpensive and easy to manufacture, while the dedicated finish machining blades are replaced less frequently and maintain precision. This segmentation accepts higher replacement frequency for simple blades in exchange for using less complex blades for the majority of the machining process.
Data Source
AI summary
A gear machining apparatus includes a rough working tool having a plurality of replaceable tool blades attached to a tool main body, such that the tool blades are arranged in a circumferential direction of the tool main body and blade tips of the tool blades are oriented outward in a radial direction of the tool main body, a finish working tool having a plurality of tool blades provided to a tool main body in a similar manner to the rough working tool, and machining controllers control to perform rough and finish machinings on the workpiece, such that the working tools are rotated on center lines in axial directions of the working tools, the workpiece is rotated on a center line in axial direction of the workpiece, and the working tools are relatively moved to the workpiece along the center line in the axial direction of the workpiece.