Gear Whirling With Twisted Axes to Reduce End Undercut
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing whirling machining method for manufacturing gears results in incomplete machined portions at both ends of the workpiece due to interference between the whirling cutter and the chuck or center, especially as the lead angle increases, leading to increased waste and inefficiency.
Innovation Solution
A manufacturing method that involves rotating a rod-shaped workpiece and a tool with a cutting edge on twisted axes, allowing synchronized relative movement to form a spiral tooth groove without slipping, with the diameter of the rolling circle being 1 to 1.5 times the tooth tip circle diameter, reducing the axis inclination angle and minimizing incomplete machined portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If whirling machining is used to manufacture gears, then gear manufacturing is achieved, but incomplete machined portions are generated at both end portions of the workpiece
Solution Approach 1:
The invention changes the inclination angle parameter of the whirling cutter axis from the conventional larger angle to a smaller angle (0° to 15°). This parameter change allows the cutter to reach closer to the end portions of the workpiece, eliminating incomplete machined portions while maintaining gear manufacturing capability
Solution Approach 2:
The invention introduces a new dimensional approach by setting the cutter axis inclination angle to 0° or close to it, making the cutter axis substantially parallel to the workpiece axis. This dimensional change in the angular parameter enables the cutting edge to contact the workpiece at positions closer to the end portions, resolving the incompleteness issue
2Adaptability or versatility
If the lead angle of the gear is increased, then the gear functionality is improved, but the incomplete machined portion becomes longer
Solution Approach 1:
The invention changes the relationship between lead angle and cutter inclination angle by decoupling them. The cutter inclination angle is independently controlled at 0° to 15° regardless of the lead angle, allowing high lead angle gears to be manufactured with minimal incomplete portions, thus reducing workpiece waste
3Productivity
If the inclination angle of the whirling cutter axis is increased, then the machining capability is improved, but the length of incomplete machined portion increases
Solution Approach 1:
The invention inverts the conventional parameter relationship by reducing the cutter inclination angle to 0° to 15° instead of increasing it. This parameter change enables the cutting edge to access positions closer to the workpiece end portions, reducing incomplete machined portion length while maintaining effective gear machining capability
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 method reduces incomplete machined portions and maintains gear accuracy by minimizing interference and undesired machining, enhancing the manufacturing efficiency and reducing waste.
Implementation Method 1
forming a spiral tooth groove on an outer peripheral surface of the workpiece by bringing the cutting edge of the tool into contact with the outer peripheral surface of the workpiece and removing a material of the workpiece at a contact position by the relative movement between the tool and the workpiece
Data Source
AI summary
A manufacturing method of a gear includes: rotating a rod-shaped workpiece around a first axis; rotating a tool having a cutting edge around a second axis at a twisted position with respect to the first axis. In a plane perpendicular to the first axis, the workpiece is rotated around the first axis and the workpiece and the tool are relatively moved in the direction parallel to the first axis at the speed synchronized with the rotation speed of the workpiece such that a contour line of the cutting edge of the tool is in rolling contact with a target contour line, which is a contour line of the spiral tooth groove to be formed, at a predetermined point of the target contour line or an extension line of the target contour line without slipping, and rotates while sliding with respect to the target contour line.