Gear Wheel Flank Polishing with Parallel Grinding Workflow
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional grinding and polishing processes for gear wheels are inefficient, as they require significant time and resources, with grinding machines being expensive and not optimized for simultaneous processing of multiple gear wheels, leading to prolonged processing times and suboptimal utilization.
Innovation Solution
A process involving separate grinding and polishing devices, where a dynamic positioning device adjusts the position and attitude of the gear wheel during polishing, allowing simultaneous grinding of a second wheel while polishing the first, using less expensive polishing devices and optimizing machine utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If grinding and polishing are performed on the same machine, then the gear wheel can be processed in sequence without repositioning, but the processing time doubles and the machine occupancy time increases
Solution Approach 1:
The patent divides the traditional combined grinding-polishing machine into two separate devices: a grinding machine for roughing and a polishing machine for finishing. This segmentation allows parallel processing where the polishing machine can work on one gear wheel while the grinding machine prepares another, effectively halving the machine occupancy time while maintaining the required surface smoothness through dedicated polishing operations.
2Ease of manufacture
If a traditional grinding machine is used for both grinding and polishing, then the process is integrated, but the machine is occupied for extended periods and cannot process multiple wheels simultaneously
Solution Approach 1:
The patent segments the manufacturing process into separate grinding and polishing operations performed on different machines. The grinding machine focuses solely on removing material to achieve the basic tooth form, while the polishing machine specializes in surface finishing. This allows the grinding machine to immediately start processing the next gear wheel after completing one, while the polishing machine finishes the previous wheel, thereby doubling overall productivity and machine utilization.
Solution Approach 2:
The grinding operation performs preliminary material removal and shaping of the gear tooth flanks before the polishing operation. By completing the roughing process on the grinding machine first, the system prepares the workpiece in advance for polishing, allowing the polishing machine to receive ready-to-finish components and maintain continuous operation without waiting for grinding to complete.
3Manufacturing precision
If polishing time is extended to achieve desired surface smoothness, then the surface quality improves, but the overall processing time increases significantly
Solution Approach 1:
The patent separates grinding and polishing into distinct operations with dedicated machines. The polishing machine is optimized specifically for surface finishing with appropriate polishing wheels and parameters, allowing it to achieve the required surface smoothness (Ra < 0.8 μm) efficiently without the time constraints of a combined machine. This specialized approach reduces polishing time while maintaining high surface quality standards.
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 reduces processing time and costs by allowing parallel processing of gear wheels, resulting in smoother surfaces with reduced frictional losses and extended wheel life, enhancing the efficiency and economic benefits of gear wheel manufacturing.
Implementation Method 1
a) providing a rotational grinding device for grinding a first portion and a second portion of a flank surface of a tooth of the first toothed wheel
Implementation Method 2
d) having the dynamic positioning device bring the first portion of the flank surface in contact with the rotating polishing body such that the first portion of the flank surface is polished by the polishing body
Data Source
AI summary
Process of grinding and polishing flank surfaces of teeth of toothed wheels, which includes a grinding device, a polishing device, a dynamic positioning device, and a toothed wheel.