Grinding Tool Pre-Profiling on Gear Grinding Machines
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Solution Overview
Problem
Existing methods for pre-profiling grinding tools are inflexible, time-consuming, and require specialized dressing masters for each workpiece shape, especially for small modules, limiting user flexibility and increasing costs.
Innovation Solution
A method and device using a gear grinding machine with a workpiece spindle, grinding spindle, and stationary profiling plate to pre-profile grinding tools, allowing on-site profiling without specialized dressing masters, suitable for gears with small modules.
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 separate dressing master is required for each workpiece shape and it is inflexible for small modules
Solution Approach 1:
The gear grinding machine is equipped with both a workpiece spindle for machining workpieces and a grinding spindle for pre-profiling grinding tool blanks. The same machine structure, control system, and spindle mechanisms serve dual purposes: machining gears and creating precise profiles on grinding tool blanks. This eliminates the need for separate dressing masters for different workpiece shapes, as the machine can be reconfigured through software and spindle positioning to handle various profiles including small modules.
Solution Approach 2:
Instead of using physical dressing masters that must be manufactured for each workpiece shape, the invention uses digital copying of the desired profile from the workpiece CAD data. The control system generates the corresponding negative profile automatically and transfers it to the grinding tool blank through coordinated spindle movements. This digital copying approach eliminates the need for physical dressing masters while maintaining high profile accuracy.
2Manufacturing precision
If pre-profiling is done on designated profiling machines, then the required rough profile can be obtained, but it is time-consuming and requires separate equipment
Solution Approach 1:
The invention combines the pre-profiling function with the gear grinding machine itself, merging what were previously separate operations (profiling on dedicated machines and subsequent grinding on gear grinders) into a single integrated system. The control system coordinates the workpiece spindle and grinding spindle to perform both workpiece machining and tool blank pre-profiling, eliminating the need for separate profiling machines and reducing total process time.
Solution Approach 2:
The invention performs pre-profiling of grinding tool blanks as a preliminary action before actual gear grinding operations. By preparing the grinding tool blanks with the required rough profile in advance using the same gear grinding machine, the subsequent gear machining process is accelerated. The control system can quickly generate the negative profile and transfer it to the tool blank, reducing setup time for production runs.
3Manufacturing precision
If rotating dressing tools are used for pre-profiling, then the profile can be created, but they can easily cause damage to the grinding tool blank
Solution Approach 1:
Instead of using a rotating dressing tool that contacts the grinding tool blank, the invention inverts the approach by making the grinding tool blank rotate on the grinding spindle while a stationary or slowly moving profile template guides the cutting action. This inversion eliminates the high-speed rotation and aggressive contact that cause damage to brittle grinding tool blanks, while still achieving precise profile creation through controlled material removal.
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, needs-oriented pre-profiling of grinding tools, reducing costs and time, and allowing for finer gear profiles, using the same device for both pre-profiling and hard finishing.
Implementation Method 1
Pre-profiling includes pre-profiling to obtain the required rough profile and dressing for fine profiling. Usually, the pre-profiling of grinding tool blanks is done once on designated profiling machines
Data Source
Figure 1A~1B
Figure 1C~2
Figure 3A~3B
AI summary
In a method for pre-profiling a grinding tool, a device, in particular a gear grinding machine (1), for hard fine machining of workpieces and for pre-profiling grinding tools is provided, which device comprises a workpiece spindle (2) for rotating a workpiece, a grinding spindle (3) that can be fed at least along an X-grinding spindle feed axis for rotating a grinding tool, in particular a grinding worm (4) or a grinding wheel, and a profiling device (5) with a stationary first profiling plate (6). A grinding tool blank, in particular a grinding worm blank, is provided on the grinding spindle (3) of the device. The device is brought into a profiling configuration. The grinding spindle (3) is fed until the grinding tool blank is in operative connection with the first profiling plate (6). Finally, the grinding tool blank is pre-profiled.