Gearwheel Grinding Sequence for Precise Head Edge Rounding

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Solution Overview

Problem

The manufacturing of head edge roundings on bevel gears requires high precision and reproducibility to ensure problem-free rolling under high torques, while existing methods face challenges in maintaining precise production tolerances and are inefficient due to potential inaccuracies from re-chucking during machining.

Innovation Solution

A method for grinding finish machining of toothed gearwheel workpieces using an NC-controlled machine tool with two separate tool spindles, where the grinding of tooth flanks and head edge roundings is performed in a specific sequence to achieve high precision and avoid burrs, eliminating the need for re-chucking and ensuring accurate dimensional accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If head edge roundings are ground using a single grinding tool and process, then the manufacturing process is simple, but manufacturing precision and tolerance maintenance deteriorate

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidhead edge rounding precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The grinding process is divided into multiple sequential steps using different grinding tools: first a form grinding tool for tooth flanks, then a special grinding tool for head edge roundings, and finally another form grinding tool for finishing. This segmentation allows each tool to be optimized for its specific function, achieving high precision while maintaining ease of manufacture through standardized tool sequences.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The method performs preliminary grinding of tooth flanks before generating head edge roundings, and then performs finishing grinding after head edge rounding. This preliminary and subsequent action approach ensures that the workpiece is properly prepared and that any burrs or inaccuracies are removed, maintaining high precision throughout the manufacturing process.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If re-chucking is performed during machining to access different regions, then complete machining is possible, but manufacturing precision deteriorates due to re-chucking inaccuracies

Engineering Contradiction:

Improvemachining accessibilityVSAvoiddimensional accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The method combines multiple grinding operations (tooth flank grinding and head edge rounding) into a single chucking sequence. The workpiece remains clamped throughout the entire process, with the machine tool changing tools and positions rather than the workpiece being repositioned. This merging eliminates re-chucking inaccuracies while maintaining complete machining capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses an intermediary approach by performing all machining operations in one setup. The machine tool system acts as the mediator, providing the adaptability to access different regions through tool changes and positioning, while the workpiece remains stationary and accurately positioned throughout, avoiding re-chucking errors.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If head edge roundings are generated before tooth flank grinding, then the process sequence is simple, but manufacturing precision deteriorates due to burr formation

Engineering Contradiction:

Improveprocess sequence simplicityVSAvoidsurface quality

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The method performs preliminary grinding of tooth flanks before generating head edge roundings. This preliminary action prepares the tooth flanks and prevents burr formation during subsequent head edge rounding. The sequence is then completed with finishing grinding to remove any burrs and achieve the required surface quality and precision.

Inventive Principle:

Principle #10Preliminary action

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 enables efficient and precise manufacturing of head edge roundings, maintaining precise production tolerances and preventing burrs, thus enhancing the reliability and performance of bevel gears under high torque conditions without introducing inaccuracies from re-chucking.

Implementation Method 1

grinding machining of at least one tooth flank of the gearwheel workpiece using the first grinding tool

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS11364560B2Method for grinding finish machining of gearwheels

Publication Date: 2022.06.21 KLINGELNBERG GMBH

AI summary

A method for the grinding finish machining of an already toothed gearwheel workpiece in an NC-controlled machine tool, comprising the following steps:a. providing the gearwheel workpiece in the machine tool,b. providing a first grinding tool in the machine tool,c. providing a second grinding tool in the machine tool,d. grinding machining of at least one tooth flank of the gearwheel workpiece using the first grinding tool,e. grinding machining of at least one tooth flank in the transition region to the tooth head of the gearwheel workpiece using the second grinding tool in the machine tool to generate a head edge rounding on the gearwheel workpiece,f. further grinding machining of at least one tooth flank of the gearwheel workpiece using the first grinding tool and/or the second grinding tool in the machine tool.