Gear Skiving Finishing for Precise Left and Right Tooth Flanks
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Solution Overview
Problem
Existing skiving methods for gearing work wheels often result in suboptimal tooth flank quality due to limitations in the machining process, particularly during finishing cuts where both tooth flanks are machined simultaneously, leading to uneven wear and reduced precision.
Innovation Solution
The method involves performing fine machining in two successive finishing cuts, where only the left or right tooth flank is machined in each cut, using mirror-symmetrical cutting wheels with different helix directions, and reversing the workpiece spindle direction between cuts to ensure precise machining of each flank, thereby improving tooth flank quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If both tooth flanks are machined simultaneously in a single finishing cut, then productivity is improved, but manufacturing precision of tooth flanks deteriorates
Solution Approach 1:
The finishing cut is segmented into two separate passes: a first finishing cut that machines only the left tooth flank, and a second finishing cut that machines only the right tooth flank. This segmentation allows each flank to be machined with dedicated attention to precision while maintaining overall productivity through systematic processing of both flanks across the two passes.
2Manufacturing precision
If mirror-symmetrical cutting wheels with different helix directions are used, then manufacturing precision of tooth flanks is improved, but device complexity increases
Solution Approach 1:
Mirror-symmetrical cutting wheels with opposite helix directions are employed to match the asymmetry of left and right tooth flanks. The first cutting wheel has a helix direction optimized for machining the left flank, while the second cutting wheel has the opposite helix direction optimized for the right flank. This asymmetric configuration enables precise machining of each flank according to its specific geometric requirements.
Solution Approach 2:
Different cutting wheels with specific helix directions are assigned to different tooth flanks based on their local geometric characteristics. The left tooth flank is machined with a cutting wheel optimized for that specific flank's geometry, and the right tooth flank is machined with a cutting wheel optimized for its geometry, ensuring locally optimal machining quality for each flank.
3Manufacturing precision
If the workpiece spindle direction is reversed between finishing cuts, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The workpiece spindle direction is periodically reversed between the first and second finishing cuts. This periodic reversal enables the use of mirror-symmetrical cutting wheels with opposite helix directions to machine each tooth flank with optimal precision. The systematic alternation of spindle direction, while introducing brief pause time, ensures that each flank receives dedicated precision machining appropriate to its geometry.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances tooth flank quality by allowing for separate and precise machining of each flank, reducing wear on cutting tools and improving the overall precision and consistency of the gearing process.
Implementation Method 1
The cutting teeth of the tool engage in a rolling engagement with the workpiece to be geared
Implementation Method 2
Due to the axis cross angle, the cutting teeth engage the workpiece in such a skiving manner that a chip removal point is created in the plane of rotation
Implementation Method 3
both the first and second finishing passes are performed with a rolling cut. The contact point of the respective cutting edge of the cutting tooth of the cutting wheel on the respective tooth flank of the tooth of the working gear moves in the incoming direction during both the first and second finishing passes, i.e., from the tooth tip of the tooth towards the tooth root of the tooth
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
The invention relates to a method and a device for gear cutting a workpiece (1) by gear skiving, wherein a first cutting wheel (2) mounted on a tool spindle (16) and having cutting teeth (11) is driven to rotate about a tool spindle axis (4), and the cutting teeth (11) engage in a machining action with a feed (V) in the direction of extension of the teeth (5) of the gear, which is carried by a workpiece spindle (15) and driven to rotate about a workpiece axis (3) located at an axial angle (a) to the tool spindle axis (4), wherein in several successive roughing passes the tooth gaps (6) between the left and right tooth flanks (7, 8) of the teeth (5) of the gear are deepened by changing the axial distance between the tool spindle axis (4) and the workpiece spindle axis (3), and subsequently in finishing passes the left and right The tooth flanks (7, 8) are finely machined.To improve the tooth flank quality, it is proposed that in a first finishing cut only the left tooth flanks (7) are machined with a chip removal point (14) that moves from the tooth head (9) to the tooth root (10) during the gear skiving motion, and in a second finishing cut only the right tooth flanks (8) are machined with a chip removal point (14) that moves from the tooth head (9) to the tooth root (10) during the gear skiving motion.