Combined Gear Skiving and Tooth Finishing Without Reclamping
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Solution Overview
Problem
Existing methods for producing gears result in increased production defects due to cumulative eccentricities from clamping errors and tool misalignments, particularly because the workpiece needs to be reclamped between machining steps, leading to tolerance-related issues.
Innovation Solution
A combination tool where the tooth machining tool and skiving wheel are rigidly connected and carried by the same tool spindle, allowing both machining steps to be performed in a single clamping position, with synchronized spindle operation and adjustable speed ratios and positions to compensate for potential eccentricities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the workpiece is reclamped between machining steps on different machine tools, then the machining process can be completed in separate operations, but cumulative eccentricities and clamping errors increase production defects
Solution Approach 1:
The patent combines the skiving wheel and tooth machining tool into a single combination tool that is mounted on one machine tool. This allows both the gearing process and tooth finishing to be performed in one clamping operation, eliminating the need to reclamp the workpiece between steps and thereby preventing cumulative eccentricities from adding up
2Manufacturing precision
If the workpiece is clamped once for both machining steps, then cumulative eccentricities are eliminated, but the tool structure becomes more complex
Solution Approach 1:
The skiving wheel and tooth machining tool are rigidly connected to form a combination tool, integrating two separate machining functions into one unified device that can be mounted on a single machine tool
Solution Approach 2:
The combination tool is designed with modular components that can be adjusted independently - the skiving wheel for gearing and the tooth machining tool for finishing, allowing each function to be optimized separately while maintaining overall integration
3Ease of manufacture
If different machine tools are used for gearing and tooth finishing, then each process can be optimized independently, but the machining time and reclamping operations increase
Solution Approach 1:
Both the skiving wheel and tooth machining tool are integrated into a single combination tool mounted on one machine tool, allowing gearing and tooth finishing to be performed sequentially in one clamping operation, thereby eliminating reclamping time and improving production efficiency
Solution Approach 2:
The combination tool enables continuous machining operations where the workpiece remains clamped throughout both the gearing and tooth finishing processes, eliminating idle time associated with reclamping and machine tool changes
Data Source
AI summary
A method for producing gears, wherein in a first step a set of teeth is formed by means of a skiving wheel rotationally driven by a tool spindle in a workpiece gear rotationally driven synchronously thereto by a workpiece spindle, wherein the workpiece spindle and the tool spindle are at an axis intersection angle to each other and the advancement occurs in the tooth-flank extension direction, and wherein in a second step at least some teeth of the set of teeth are machined by means of a tooth-machining tool. A combined tool is used, in the case of which the toothmachining tool and the skiving wheel are fixedly connected to each other. Between the two steps, the combined tool remains connected to the tool spindle and the workpiece gear remains connected to the workpiece spindle. Between the two steps, merely the relative position of the tool spindle in relation to the workpiece spindle and the rotational speed ratio of the two spindles are changed.