Adjustable Gear Undercut Tool for Wide-Tooth Machining Precision
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Solution Overview
Problem
Existing tools struggle to produce high-precision deposits on gear-shaped workpieces, especially with wide teeth, due to deformation under high loads, which affects the accuracy and position of the deposits during machining.
Innovation Solution
A tool with an elongated peg-like carrier and adjustable cutting edges that can compensate for deformation by adjusting the position of at least one cutting edge relative to the other, ensuring precise alignment and shape of the deposits despite tool carrier or holder deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the tool holder is made longer to machine wide gears, then the machining capability for wide gears is improved, but the tool holder deforms under high loads
Solution Approach 1:
The cutting edges are made adjustable relative to each other along the longitudinal axis, allowing the tool to dynamically adapt to deformations of the tool holder. This enables the cutting edges to maintain correct positioning even when the tool holder bends or twists under load, resolving the contradiction between needing a long tool holder for wide gears and maintaining manufacturing precision.
Solution Approach 2:
The position parameters of the cutting edges can be changed during operation to compensate for tool holder deformation. By adjusting the longitudinal positions of cutting edges independently, the system adapts to varying load conditions and maintains accurate deposit geometry despite changes in tool holder rigidity.
2Manufacturing precision
If the tool holder is stiffened to prevent deformation, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
Rather than making the tool holder statically stiffer and more complex, the invention introduces dynamic adjustability of the cutting edges. This allows the system to compensate for deformation through movement and repositioning rather than through increased structural rigidity, maintaining precision without proportionally increasing complexity.
Solution Approach 2:
The system changes the approach from modifying the structural parameters of the tool holder to adjusting the positional parameters of the cutting edges. This parameter change enables precision maintenance through simple positional adjustments rather than complex structural modifications.
3Productivity
If the cutting edges are arranged axially parallel to the central axis, then two backings can be created simultaneously, but the tool holder deforms under transverse forces
Solution Approach 1:
The cutting edges are made independently adjustable in position, allowing them to dynamically compensate for tool holder deformation while maintaining their axial arrangement for simultaneous machining. This dynamic adjustment capability preserves both productivity and stability under load.
Solution Approach 2:
The adjustability mechanism provides a form of mechanical feedback, allowing the cutting edges to be repositioned in response to observed or anticipated deformations, thereby maintaining correct geometric relationships despite tool holder instability under transverse forces.
Data Source
Figure 1
Figure 2~3
AI summary
The invention provides a tool (1) that enables the high-precision, simultaneous production of two backings on the tooth flanks of the teeth of a gear-shaped workpiece, regardless of their width. For this purpose, the invention provides that the tool (1) comprises a pin-shaped, elongated tool carrier (2) aligned coaxially with its central longitudinal axis (L) and at least two cutting edges (5, 6) which, in use, engage with the respective tooth of the gear-shaped workpiece to be machined, wherein the cutting edges (5, 6) are spaced apart from each other in the longitudinal direction (LR) of the tool carrier (2) and their width (B) each extends over a partial length of the tool carrier (2).According to the invention, the position of at least one of the cutting edges (6) is adjustable relative to the other cutting edge (5) to compensate for deformations of the tool holder (2) that occur during use. The invention also describes a method for simultaneously creating at least two backings on the teeth of a gear-shaped workpiece using a tool according to the invention.