Gear-Cutting Tool Regrinding for Accurate Batch Tooth Profiles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing gear-cutting tools often fail to produce the exact tooth profile on workpieces, especially in large workpiece batches, leading to significant burdens in subsequent hard-fine machining and difficulty in compensation, particularly when deviations are large.
Innovation Solution
Implement a method that adjusts the position of rake faces on the gear-cutting tool by regrinding, using a grinding machine integrated with the gear-cutting machine, to correct deviations dynamically, thereby reducing the need for machine axis corrections during machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dynamic corrections via machine axis adjustments are used to compensate for tooth profile deviations, then manufacturing precision is improved, but tool service life deteriorates due to increased process forces and load on the gear-cutting tool
Solution Approach 1:
The patent applies preliminary action by modifying the rake face position of the gear-cutting tool before machining operations begin. The rake faces are ground to a modified position that pre-compensates for expected tooth profile deviations, eliminating the need for dynamic corrections during machining and thereby protecting the tool from excessive loads
Solution Approach 2:
The patent changes the geometric parameters of the tool by modifying the rake face position relative to the tool axis of rotation. This parameter change allows the tool to produce accurate tooth profiles without requiring dynamic axis corrections, thus extending tool service life while maintaining manufacturing precision
2Adaptability or versatility
If structural changes to the tool (regrinding rake faces) are implemented to correct tooth profile deviations, then tool flexibility is improved, but device complexity increases due to the need for integrated grinding capability
Solution Approach 1:
The patent merges the gear-cutting function and the grinding function into a single integrated machine group. The grinding device is combined with the gear-cutting machine, allowing rake face modification to be performed on the same equipment without requiring separate standalone grinding machines, thus managing complexity while improving flexibility
Solution Approach 2:
The machine group is designed with multi-functionality, capable of both gear-cutting operations and rake face grinding operations. This universal equipment can adapt to different machining requirements and tool reconditioning needs, enhancing flexibility while consolidating equipment rather than adding separate specialized machines
3Manufacturing precision
If dynamic corrections are applied during machining of large workpiece batches, then manufacturing precision is maintained, but productivity deteriorates due to increased burden on subsequent hard-fine machining processes
Solution Approach 1:
By pre-modifying the rake face position before machining large batches of workpieces, the patent eliminates the need for time-consuming hard-fine machining operations later. The tool is prepared in advance to produce accurate tooth profiles directly, significantly improving productivity for large production batches while maintaining high manufacturing precision
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 enhances tool flexibility and service life by minimizing dynamic corrections, allowing quick reconditioning of gear-cutting tools for precise tooth profile production across various workpiece batches.
Implementation Method 1
grinding performed on the gear-cutting machine or at a grinding machine that belongs to the machine group of the gear-cutting machine
Data Source
AI summary
The invention relates to a method for producing or machining, by cutting, an identical set of teeth on each of a plurality of workpieces, in particular at least 4 workpieces, of a workpiece batch on one or more gear-cutting machines (100) having a gear-cutting tool (S), which has a set of teeth having rake faces (5) and having an axis of rotation (B1), in rolling machining engagement, in which method, in the event that a deviation of a set of teeth from the tooth profile sought for said set of teeth is detected or expected, a countermeasure that counteracts said deviation is determined and the production/machining of additional workpieces of said workpiece batch is continued using the countermeasure, the countermeasure being, at least in part, a change in the position of the rake faces relative to the axis of rotation of the tool, which change is brought about by means of grinding performed on the gear-cutting machine or at a grinding machine (140) that belongs to the machine group of the gear-cutting machine.