Grinding Tool Pre-Profiling Using a Fixed Profiling Plate
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Solution Overview
Problem
Existing methods for pre-profiling grinding tools are inflexible, require specific dressing masters for each workpiece shape, and are time-consuming, especially for small workpieces, limiting user flexibility and incurring financial burdens.
Innovation Solution
A method and device using a gear grinding machine with a workpiece spindle, a grinding spindle, and a fixed profiling plate to pre-profile grinding tools, allowing for demand-oriented and flexible pre-profiling without the need for specific dressing masters, enabling rapid and efficient production of fine profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a dressing master is used for pre-profiling, then the profile can be transferred to the grinding tool blank, but a specific dressing master is required for each workpiece shape which reduces flexibility and increases device complexity
Solution Approach 1:
The invention uses a digital copy (CNC program) of the workpiece profile instead of a physical dressing master. The contour data of the workpiece is stored digitally and used to control the profiling device, eliminating the need for physical dressing masters for each workpiece shape while maintaining profile accuracy.
Solution Approach 2:
The invention replaces the mechanical dressing master system with a CNC-controlled profiling device that uses digital information. Instead of physical contact with a dressing master, the profiling device follows digital contour data to create the profile, substituting mechanical replication with computer-controlled machining.
2Adaptability or versatility
If line dressing with radius profile rollers is used for pre-profiling, then flexibility is achieved, but the process becomes time-consuming and reduces productivity
Solution Approach 1:
The invention replaces the slow mechanical line dressing process with a CNC-controlled profiling device that can rapidly reproduce profiles. The digital control system enables much faster material removal rates while maintaining the flexibility to adapt to different workpiece shapes through software programming.
Solution Approach 2:
The invention performs preliminary digital preparation of the profile data before machining. The contour data is pre-programmed into the CNC system, allowing the profiling device to execute the pre-profiling operation rapidly without the time-consuming iterative adjustments required by traditional line dressing methods.
3Device complexity
If pre-profiling is performed by suppliers rather than users, then specialized equipment is avoided, but user flexibility is limited and financial burden increases
Solution Approach 1:
The invention makes the gear grinding machine itself capable of pre-profiling operations through the integrated profiling device. This multi-functional approach allows the same machine to perform both pre-profiling and subsequent generating grinding, eliminating the need for separate specialized pre-profiling equipment while giving users full flexibility.
Solution Approach 2:
The invention enables users to perform pre-profiling themselves using the integrated profiling device and CNC control system. Users can independently create profiles for different workpiece shapes by programming the contour data, making the machine self-sufficient and eliminating dependence on suppliers for pre-profiled tools.
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
Enables flexible and demand-oriented pre-profiling of grinding tools, reducing the need for specialized tools, allowing for rapid and efficient production of fine profiles, and simplifying the process by eliminating the use of cooling oil.
Implementation Method 1
pre-profiling the grinding tool blank
Data Source
AI summary
In a method for pre-profiling a grinding tool, a device, in particular a gear grinding machine, for hard fine machining of workpieces and for pre-profiling grinding tools is provided, which includes a workpiece spindle for rotating a workpiece, a grinding spindle, which is feedable at least along an X-grinding-spindle-infeed-axis, for rotating a grinding tool, in particular a grinding worm or a grinding wheel, and a profiling device with a fixed first profiling plate. A grinding tool blank, in particular a grinding worm blank, is provided on the grinding spindle of the device. The device is brought into a profiling configuration. The grinding spindle is fed until the grinding tool blank is operatively connected to the first profiling plate. Finally, the grinding tool blank is pre-profiled.