Gear Tooth Chamfering With Rolling Toothed Machining
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Solution Overview
Problem
Existing methods for supplementary tooth shaping, particularly in gear manufacturing, often fail to produce high-quality chamfers with precise tolerances, leading to suboptimal tooth edge geometry and potential material deformations.
Innovation Solution
A method utilizing toothed machining tools that perform chamfering on one tooth end edge in a single operation, with subsequent machining on the opposite edge if necessary, employing peeling wheels with specific axis crossing angles to create precise chamfers by simulating and controlling machining paths based on gear data and chamfer parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If toothed machining tools are used to plastically deform tooth edges by pressing in a rolling machining action, then material is compacted and displaced, but secondary burrs are formed on tooth flanks and face edges
Solution Approach 1:
The machining process is segmented into multiple operations: first removing primary burrs with a stationary deburring tool, then forming chamfers with a first toothed machining tool, and finally removing secondary burrs with a second toothed machining tool. This segmentation allows each operation to address specific issues without creating unnecessary problems.
Solution Approach 2:
The patent converts the harmful secondary burrs generated by plastic deformation into beneficial chamfered surfaces by carefully controlling the deformation process and subsequent removal operations, transforming a defect into a desired geometric feature.
2Manufacturing precision
If chamfer is produced by cutting with a cutting wheel, then precise chamfer geometry can be achieved, but the cutting wheel axis must be pivotable by 180° to machine both upper and lower face ends
Solution Approach 1:
The patent combines multiple machining functions into integrated tool arrangements where toothed machining tools are mounted on rotatable spindles that can be positioned at different angles, eliminating the need for separate cutting wheels and complex 180° pivoting mechanisms while achieving the same machining results.
Solution Approach 2:
The toothed machining tools serve multiple functions: they can machine both upper and lower face ends of teeth, remove primary and secondary burrs, and form chamfers with different geometries by adjusting the spindle angle, replacing what would otherwise require multiple specialized tools.
3Manufacturing precision
If multiple machining operations are performed to achieve high-quality chamfers with tight tolerances, then precise chamfer geometry is achieved, but machining time and process complexity increase
Solution Approach 1:
The patent implements continuous machining operations where the workpiece remains clamped and rotated throughout the entire process, with tools sequentially engaging different surfaces without requiring workpiece removal or repositioning, thereby maintaining continuous productive action.
Solution Approach 2:
The first toothed machining tool performs preliminary chamfer formation and secondary burr removal before the second tool completes the finishing operations, preparing the surface in advance to reduce the workload and time required for final precision machining.
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
Enables the production of high-quality chamfers with tight tolerances by creating new helical gearing near the tooth edges, ensuring precise and repeatable results even within narrow tolerance ranges.
Implementation Method 1
a first toothed machining tool is used to machine a chamfer on one of the two tooth end faces belonging to a tooth gap
Implementation Method 2
toothed chamfering tools are used to plastically deform the tooth edges by pressing in a rolling machining action. The material of the tooth edge is plastically deformed, compacted, and displaced.
Data Source
Figure 1
Figure 2
Figure 3a~3c
AI summary
The invention relates to a method for machining a set of teeth, wherein, in order to form a chamfer on a tooth edge formed between an end face of the set of teeth and a tooth flank associated with a tooth space of the set of teeth, material is removed from the tooth edge in a cutting manner by means of a machining tool provided with a cutting edge, which machining tool is in machining engagement, wherein the machining tool is toothed and the machining engagement is a rolling machining engagement that occurs with an axis intersection angle between the rotational axes of the machining tool and of the set of teeth and that does not extend beyond the tooth base region of the tooth gap.