Gear Tooth Edge Machining Using Axis-Crossing Rolling Engagement
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Solution Overview
Problem
Existing methods for machining gear tooth edges fail to effectively remove burrs without causing secondary damage or requiring additional steps, such as carburization, which can lead to premature wear of tools and safety hazards.
Innovation Solution
A machining method using a tool with a toothed contour that is positioned at an axis-crossing angle relative to the gear axis, allowing for a cutting operation that includes a directional component along the tooth width and orthogonal to the tooth flank, enabling efficient removal of burrs without secondary burr generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the tooth edge is merely deburred without cutting, then the burr is removed, but the tooth edge becomes glass-hard through carburization and may break away under stress
Solution Approach 1:
The patent replaces light mechanical contact (deburring only) with controlled material removal through cutting. The cutting process removes the burr and a small portion of the tooth edge material, preventing the formation of glass-hard layers that would occur with mere deburring, thereby maintaining tooth edge strength and preventing breakage under stress
2Object-generated harmful factors
If a cylindrical tool is used for chamfering with radial infeed, then the burr is removed, but the method lacks flexibility for various tooth shapes
Solution Approach 1:
The patent enhances the universality of the cylindrical chamfering tool by combining it with controlled axial and radial feed movements. This multi-directional feeding capability allows the same tool to effectively machine various tooth shapes and configurations, making the process adaptable to different gear types while maintaining burr removal effectiveness
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 allows for flexible machining of various tooth shapes, reduces the risk of tool wear, and eliminates the need for additional steps, enhancing safety and efficiency by ensuring complete machining of tooth edges without secondary burr formation.
Implementation Method 1
a cutting operation wherein a machining tool, rotating about the axis of its toothed contour, is brought into rolling engagement with the toothed workpiece
Data Source
AI summary
The invention concerns a method for the machining of the tooth edges between an axially facing surface and the tooth flanks of a gear with a machining tool that has a toothed contour. For the material-removing cutting operation, the machining tool, rotating about the axis of its toothed contour, is brought into rolling engagement with the toothed workpiece under a crossing angle different from zero between the rotary axes of the machining tool and the toothed workpiece.