Gear Tooth Tip Circle Machining with Angled Disk Tool Sweeping
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Solution Overview
Problem
Current methods for machining the tip circle diameter of gearwheels are inefficient and lack precision, often resulting in stress on the tooth material and requiring multiple clamping and repositioning steps.
Innovation Solution
A disk-shaped tool is used to machine the tip surface of gearwheel teeth, with a relative axial movement between the tool and gearwheel, oriented at an intersection angle of 5° to 40°, allowing for precise and efficient removal of material from the tip circle diameter using hob peeling kinematics without adapting to the tooth system's shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional lathing machining is used for tip circle diameter, then machining can be performed, but it requires multiple clamping and repositioning steps which reduces productivity
Solution Approach 1:
The patent combines the hob peeling process and tip circle diameter machining into a single integrated process. The disk-shaped tool is mounted on the same tool spindle as the hob peeling tool, allowing both operations to be performed in one clamping position without repositioning the workpiece or tool spindle, thereby eliminating time loss associated with multiple clamping steps
2Manufacturing precision
If conventional machining methods are used, then tip circle diameter can be machined, but precision and uniformity are insufficient
Solution Approach 1:
The patent changes the machining parameters by using hob peeling kinematics instead of traditional lathing. The disk-shaped tool rotates about a tool axis oriented at an axial distance from the workpiece axis, creating a specific relative motion pattern that ensures uniform material removal and precise tip circle diameter while reducing stress on the tooth material through controlled chip removal
3Productivity
If a combination tool is used for hob peeling and tooth machining, then two operations can be performed in one clamping, but the tool structure becomes complex
Solution Approach 1:
The patent uses a disk-shaped tool that can perform both hob peeling and tip circle diameter machining functions. The same disk-shaped tool is used for both operations by adjusting the relative position and rotation speed, eliminating the need for separate specialized tools and reducing overall tool structure complexity while maintaining multi-functionality
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 method enables time-saving and precise machining of the tip circle diameter, reducing stress on the tool and gearwheel, while allowing for uniform or selective machining of teeth, and can be integrated with existing hob peeling processes for optimized production.
Implementation Method 1
at least one tooth of the tooth system of the gearwheel is machined by means of a tool, by removing chips
Data Source
AI summary
The invention relates to a method for machining the tip circle diameter of a tooth system (4) of a gearwheel (6), in which the gearwheel (6) rotates about a workpiece axis of rotation (Rw), and in which at least one tooth (9) of the tooth system (4) is machined, by removing chips, by means of a tool (7, 7′) that rotates about a tool axis of rotation (Rz) oriented at an axial distance (A′, A″) relative to the workpiece axis of rotation (Rw). According to the invention, the tool (7, 7′) is disk-shaped, the disk-shaped tool (7, 7′) machines the tip surface (8) of the tooth (9), by removing chips, with at least one partial segment (10a) of its circumferential edge configured as a defined blade (10), wherein a relative movement between the tool (7, 7′) and the gearwheel (6), oriented in the axial direction of the tooth system (4), is carried out during the chip-removing machining, as a consequence of which movement the tool (7, 7′) sweeps over the tip surface (8), and the tool axis of rotation (Rz) is oriented at an axis intersection angle (Σ″) of 5° to 40° with respect to the workpiece axis of rotation (Rw). In this way, efficient and highly precise machining of the tip circle diameter is made possible. The invention also states a method for producing a gearwheel, in which the tooth system (4) is produced on a gearwheel blank (5) by means of hob peeling before machining of the tip circle diameter according to the invention, as well as a combination tool, in which a hob-peeling wheel for producing the gearwheel and a disk-shaped tool for machining the tip circle diameter according to the invention are combined with each other.