Gear Grinding Worm Control for Precision and Tool Life
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Solution Overview
Problem
Existing grinding technologies for generating gear workpieces with grinding worms face inefficiencies in tool wear and precision, particularly in maintaining high economic efficiency and reproducible precision throughout the grinding process.
Innovation Solution
A method utilizing a dressable grinding worm with adjustable ratios between shifting and axially parallel relative movements, adjusted step-by-step after dressing processes, to optimize the engagement density and maintain consistent meshing density during grinding, thereby extending the tool's lifespan and improving precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a constant ratio between shifting and stroke path is used in conventional generating grinding, then the grinding process is simple to control, but the tool wear increases and precision deteriorates over time
Solution Approach 1:
The patent applies dynamics by making the ratio between shifting and stroke path variable rather than constant. The control system dynamically adjusts this ratio based on the dressing state of the grinding worm, transitioning from a first ratio before dressing to a second ratio after dressing. This dynamic adjustment optimizes both precision and tool service life throughout the grinding process.
Solution Approach 2:
The patent changes the parameter of the shifting-to-stroke path ratio based on the dressing state of the grinding worm. By monitoring whether the worm is dressed or undressed and adjusting the ratio accordingly, the system optimizes grinding performance and extends tool life without compromising precision.
2Manufacturing precision
If the grinding worm is dressed frequently to maintain precision, then grinding precision is maintained, but productivity decreases due to increased downtime
Solution Approach 1:
The patent uses dynamic adjustment of the shifting-to-stroke path ratio to extend the effective service life of the grinding worm. By adapting the ratio to the dressing state, the system maintains precision for more workpieces between dressings, reducing the frequency of dressing operations and increasing overall productivity.
Solution Approach 2:
The control system changes the grinding parameters (shifting-to-stroke path ratio) based on the dressing state, allowing the worm to operate effectively for more workpieces before requiring dressing. This parameter adaptation reduces downtime and increases the number of workpieces that can be processed with a single worm.
3Object-affected harmful factors
If continuous shifting is used to prevent thermal damage, then surface quality is maintained, but the complexity of controlling multiple coordinated movements increases
Solution Approach 1:
The patent implements feedback by using the dressing state of the grinding worm as a control input to automatically adjust the shifting-to-stroke path ratio. The control system receives information about whether the worm is dressed or undressed and automatically selects the appropriate ratio, simplifying the control process while maintaining surface quality and preventing thermal damage.
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 enhances the grinding efficiency and precision of gear workpieces by adjusting the shifting and axially parallel movement ratios based on the grinding worm's diameter, allowing for consistent high-quality processing of multiple workpieces without deteriorating surface quality, thereby increasing the number of workpieces that can be processed with a single grinding worm.
Implementation Method 1
a grinding tool (2) and a workpiece spindle (3) with a workpiece (W1). This illustration also shows some of the axes that can be used for generating grinding the workpiece W1
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3B
AI summary
A method for generating a gear workpiece (W1) using a dressable grinding worm (2), wherein during the generating grinding process the grinding worm (2) is driven to rotate about a tool rotation axis (B) and the gear workpiece (W1) is driven to rotate about a workpiece rotation axis (C), and relative movements are performed between the grinding worm (2) and the gear workpiece (W1), and wherein after performing a dressing operation of the grinding worm (2), which is carried out by means of a rotary-driven dresser (4), the following steps are performed: - performing a relative shift movement between the grinding worm (2) and the gear workpiece (W1) parallel to the tool rotation axis (B), - performing an axis-parallel relative movement between the grinding worm (2) and the gear workpiece (W1) parallel or oblique to the workpiece rotation axis (C),where a ratio between the shift movement and the axis-parallel relative movement is specified, which is variable.