Gear Tooth Geometry Correction via Diagonal Tool Dressing
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Solution Overview
Problem
Existing methods for manufacturing gear teeth with corrected geometry and modified surface structures lack practical strategies for achieving desired modifications, particularly in achieving precise crowning and twist, and fail to provide effective iteration processes for tool manufacturing.
Innovation Solution
A method involving a modified tool with specific surface geometry modifications, where the tool's geometry is adjusted using diagonal feed generating methods, allowing for superposition of profile modifications and machine kinematics variations to produce desired gear tooth geometries and surface structures, utilizing curve fitting to determine optimal tool parameters and machining processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a crowned tool is used with varied axial spacing during dressing to achieve required crowning and twist, then the gear tooth geometry can be corrected, but the manufacturing process becomes complex and lacks practical iteration strategies
Solution Approach 1:
The patent segments the gear tooth modification into two independent components: profile modification (in the generating direction) and trace modification (in the width direction). This segmentation allows each modification type to be controlled by separate tool parameters, simplifying the dressing process while maintaining manufacturing precision. The profile modification is achieved through tool profile geometry, while trace modification is achieved through tool width geometry, enabling independent optimization of each aspect.
Solution Approach 2:
The patent applies preliminary action by pre-calculating and pre-setting the tool geometry to incorporate the desired modifications. The tool is dressed with predetermined profile and trace modifications before the actual gear manufacturing process, eliminating the need for complex real-time adjustments during machining. This preliminary preparation of the tool geometry ensures consistent and precise gear tooth modifications are achieved directly during the generating process.
2Manufacturing precision
If iterative simulation is used to determine tool modifications for achieving required crowning and twist, then accurate gear geometry can be produced, but the manufacturing time and process complexity increase significantly
Solution Approach 1:
The patent uses copying by directly transferring the desired gear tooth modification profile and trace from the design stage to the tool geometry stage. Instead of iterative simulation, the tool is dressed with a copy of the required modification geometry, which is then replicated onto the gear teeth during manufacturing. This direct copying approach maintains geometric accuracy while eliminating time-consuming iterative processes.
Solution Approach 2:
The patent applies parameter changes by directly adjusting the tool geometry parameters (profile shape, width distribution, axial spacing) to match the desired gear modification parameters. By establishing direct mathematical relationships between tool parameters and gear modification outcomes, the patent enables precise control of gear geometry through simple parameter setting rather than iterative simulation, significantly reducing the time required while maintaining accuracy.
3Adaptability or versatility
If multiple modifications are superposed on the tool surface geometry, then diverse gear tooth geometries and surface structures can be achieved, but the tool manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by applying different modification types to different local regions of the tool surface. Profile modifications are applied to the tool profile in the generating direction, while trace modifications are applied to the tool width in the transverse direction. This localized application of different modification qualities allows diverse gear tooth geometries to be achieved through simple, region-specific tool dressing operations rather than complex overall tool manufacturing.
Solution Approach 2:
The patent merges profile modification and trace modification into a single unified tool dressing process. Both modifications are incorporated into the tool geometry simultaneously through one dressing operation, rather than requiring separate manufacturing steps. This merging of modification functions into a single process simplifies tool manufacturing while enabling the production of gears with combined profile and trace modifications, achieving versatility without increasing manufacturing complexity.
Data Source
AI summary
A method for production of a workpiece having a corrected gear tooth geometry and/or a modified surface structure by a diagonal generating method with a modified tool, wherein a modification in the generating pattern has a constant value in a first direction of the tool and is given by a function FFt1 in a second direction of the tool, which extends perpendicular to the first direction, and/or wherein the modification is produced in that the position of the dresser to the tool is varied during dressing in dependence on the angle of rotation of the tool and/or on the tool width position, wherein the modification of the tool produces a corresponding modification on the surface of the workpiece, and wherein the modification of the workpiece produced by the modification is superposed by a profile modification and/or a modification caused by a change of the machine kinematics during the machining process.