Asymmetrical Gear Skiving Cutter for Uniform Grinding Allowance
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Solution Overview
Problem
Conventional gear skiving processes result in uneven grinding allowances on gear workpieces due to asymmetrical cutting edge profiles, leading to reduced precision and increased grinding costs.
Innovation Solution
A designing method for gear skiving cutters involves constructing a cutter manufacturing tool with asymmetrical grinding allowance structures and simulating relative movements to create a gear skiving cutter with controlled cutting surface shapes, ensuring uniform grinding allowances on both sides of each tooth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional gear skiving cutters with symmetrical tooth structures are used, then the manufacturing process is simple, but uneven grinding allowance is produced on both sides of each tooth
Solution Approach 1:
The patent applies asymmetry by designing the gear skiving cutter with different tooth profiles on opposite sides. Specifically, the first side portion has a different tooth profile than the second side portion, creating intentional asymmetry in the cutter structure. This asymmetrical design allows the cutter to generate different grinding allowances on each side of the gear workpiece teeth, thereby achieving uniform grind allowance distribution and eliminating the precision problem caused by conventional symmetrical cutters.
2Device complexity
If conventional symmetrical tooth profiles are used, then the cutter design is straightforward, but tooth surface profile errors increase
Solution Approach 1:
The patent implements asymmetry in the cutter tooth profiles where the first side portion and second side portion have different geometries. The first tooth profile and second tooth profile are designed differently to compensate for the inherent asymmetry in gear tooth grinding requirements. This approach improves tooth surface profile accuracy by eliminating errors that would otherwise result from using identical symmetrical profiles on both sides of the cutter.
3Productivity
If conventional gear skiving cutters are used, then the machining process is fast, but grinding period and costs increase
Solution Approach 1:
The patent applies preliminary action by pre-configuring the cutter with asymmetrical tooth profiles that are specifically designed to produce uniform grinding allowances directly during the skiving process. This preliminary design of the cutter geometry eliminates the need for extensive subsequent grinding operations to correct uneven allowances, thereby reducing the grinding period and associated costs while maintaining fast skiving machining speeds.
Data Source
AI summary
A designing method of a gear skiving cutter that includes: constructing a cutter manufacturing tool with a plurality of asymmetrical tooth structures and a base material for the gear skiving cutter; simulating relative movements of the cutter manufacturing tool and the base material based on multi-axes in a relative motion coordinate system to have the cutter manufacturing tool process the surface of the base material; and forming a plurality of cut teeth on the base material by the plurality of tooth structures of the cutter manufacturing tool. An outer contour of each cut tooth is designed in advance so that gear teeth on a gear workpiece with a planned grinding allowance can be formed when the gear workpiece is processed by the gear skiving cutter. The grinding allowance on either side of each gear tooth can be kept uniform, and the grinding allowance on both sides of each gear tooth can be closely the same.