Gear Tip Diameter Machining With Cross-Axis Disc Cutting
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Solution Overview
Problem
Current methods for machining the addendum circle diameter of gear wheels lack efficiency and precision, often requiring additional operations and tools, which can lead to inaccuracies and increased production time.
Innovation Solution
A method utilizing a disk-shaped tool with a defined cutting edge on its peripheral edge, aligned at a cross-axis angle of 5° to 40°, for machining the top surface of gear teeth, allowing for precise material removal and integration with existing skiving processes to optimize the tip circle diameter machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional turning operation is used to machine the addendum circle diameter after skiving, then the gear teeth can be processed, but production time increases and manufacturing precision decreases
Solution Approach 1:
The patent combines the skiving operation and addendum circle diameter machining into a single continuous process. The skiving tool is designed to perform both tooth generation and tip diameter machining in one setting, eliminating the need for separate turning operations and reducing production time while maintaining precision.
Solution Approach 2:
The skiving tool is designed with multi-functionality to perform both the primary skiving operation and the secondary addendum circle diameter machining. The tool includes multiple cutting edges that can be selectively engaged to perform different machining functions, reducing the need for tool changes and setup time.
2Manufacturing precision
If multiple separate operations are used for gear production, then each operation can be optimized, but device complexity and setup requirements increase
Solution Approach 1:
The patent merges multiple machining operations into a single integrated skiving process. The tool holder and skiving tool are designed to accommodate multiple cutting functions in one device, reducing the number of separate operations and setups required while maintaining the precision benefits of specialized operations.
3Productivity
If a disk-shaped tool with cross-axis angle is used for machining, then machining efficiency and precision improve, but tool design complexity increases
Solution Approach 1:
The patent employs a dynamic tool design where the disk-shaped tool can be positioned and oriented at specific cross-axis angles during the skiving operation. The tool holder allows for adjustable positioning to achieve optimal cutting angles, enabling efficient material removal while managing design complexity through modular positioning mechanisms.
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 enables efficient and accurate machining of the tip circle diameter, reducing production time and avoiding tool overload, while maintaining high manufacturing accuracy and allowing for synchronized operation with existing skiving processes.
Implementation Method 1
a disk-shaped tool (7), which rotates around a tool axis of rotation (Rz) aligned at an axis distance to the axis of rotation (Rw) of the workpiece,machines the top surface (8) of the tooth (9) to be machined with at least one partial segment of its peripheral edge designed as a defined cutting edge (10)
Data Source
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AI summary
The invention relates to a method for machining the tip circle diameter of a tooth (4) of a gear (6), in which the gear (6) rotates about a workpiece rotation axis (Rw) and in which at least one tooth (9) of the tooth (4) is machined by means of a tool (7,7') which rotates about a tool rotation axis (Rz) aligned at an axial distance (A',A") to the workpiece rotation axis (Rw).According to the invention, the tool (7, 7') is disc-shaped. The disc-shaped tool (7, 7') machined the tooth head (8) (9) by removing material with at least one segment (10a) of its circumferential edge, which is designed as a defined cutting edge (10). During the machining process, a relative movement oriented axially to the tooth (4) is performed between the tool (7, 7') and the gear (6), as a result of which the tool (7, 7') sweeps over the tooth head (8). The tool's axis of rotation (Rz) is aligned with respect to the workpiece's axis of rotation (Rw) at an axis cross angle (Σ") of 5° to 40°. This enables efficient and highly precise machining of the tooth head diameter.The invention also mentions a method for manufacturing a gear in which the teeth (4) are produced on a gear blank (5) prior to the machining of the tip circle diameter according to the invention by gear skiving, as well as a combination tool in which a gear skiving wheel for producing the gear and a disc-shaped tool for machining the tip circle diameter according to the invention are combined together.