Gear Tooth Machining with Phase-Shifted Rolling Coupling
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Solution Overview
Problem
Existing gear machining methods lack flexibility and precision in adjusting tooth head height and tip circle diameter, often requiring additional tools and resulting in potential clamping errors due to mismatched rotational axes.
Innovation Solution
A phase-shifted machining approach where the workpiece toothing is machined relative to the regular rolling coupling, allowing for flexible machining of tooth heads without additional tools, maintaining synchronization of rotational axes and enabling precise adjustment of tooth tip diameter and surface formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If regular rolling coupling is used for gear machining, then the machining process is simple, but the flexibility to adjust tooth tip height and the precision of tip circle diameter are insufficient
Solution Approach 1:
The patent applies a phase-shifted rolling coupling where the phase shift is dynamically adjusted to position tool tooth tips at the workpiece tooth tip region. This dynamic positioning enables precise control of tooth tip height and tip circle diameter without requiring additional tools or complex setups, resolving the contradiction between precision and complexity.
Solution Approach 2:
The patent changes the phase shift parameter of the rolling coupling to achieve different machining objectives. By adjusting the phase shift, the same tool can machine different regions of the workpiece gear, including tooth tips, root areas, and full profiles, thereby achieving high precision tooth tip machining without increasing device complexity.
2Adaptability or versatility
If additional tools are used for machining tooth tips, then the precision and flexibility are improved, but the device complexity and process simplicity are worsened
Solution Approach 1:
The patent makes the tool gear universal by enabling it to perform multiple functions through phase-shifted rolling coupling. The same tool can machine tooth profiles, tooth tips, and root areas by simply adjusting the phase shift, eliminating the need for separate tools for different machining operations and maintaining process simplicity while improving versatility.
Solution Approach 2:
The patent uses dynamic phase shift adjustment to enable a single tool to adapt to different machining requirements. By dynamically changing the phase relationship between tool and workpiece, the tool can selectively machine different regions, achieving high adaptability without increasing the number of tools.
3Manufacturing precision
If different rotational axis references are used for positioning and machining, then the adaptability is improved, but the positioning precision and clamping accuracy are worsened
Solution Approach 1:
The patent segments the machining process into two distinct operations: a first operation for creating the workpiece gear with a first rotational axis reference, and a second operation for machining tooth tips with a second rotational axis reference. This segmentation allows each operation to have its own optimized reference system while maintaining overall positioning accuracy through the phase-shifted coupling mechanism.
Solution Approach 2:
The patent introduces a phase shift dimension to the traditional rolling coupling, transforming it from a single-reference system to a multi-reference system. This additional dimensional parameter enables the system to accommodate different rotational axis references for positioning and machining operations while maintaining high positioning accuracy and clamping flexibility.
Data Source
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AI summary
The invention relates to a method for machining or producing a toothed portion (2) on a workpiece by means of a tool toothed portion (4), wherein the tool toothed portion is brought into a first machining engagement with the rotating workpiece toothed portion clamped in a clamped setup, such that there is rolling coupling which assigns the teeth of the tool toothed portion to the tooth spaces of the workpiece toothed portion, and wherein the tool toothed portion is brought into a second machining engagement phase-shifted by at least one fourth of the pitch in comparison with the rolling coupling of the first machining engagement at the machining distance of deepest advancement, said second machining engagement having increased machining distance from the workpiece toothed portion clamped in the same clamped setup of the first machining engagement in comparison with the deepest advancement of the first machining engagement. The invention also relates to a control program having control instructions, which, when executed on a controller of a gear cutting machine, cause said gear cutting machine to carry out the method. The invention also relates to a gear cutting machine therefor.