Grinding Worm Dressing Roller for Variable Tooth Flank Roughness
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing dressing rollers used for grinding worms produce a uniform surface roughness along the tooth height, which is not always desirable, as they lack the ability to specifically influence the surface roughness across the tooth flank height.
Innovation Solution
The profiling of the dressing roller's base body with abrasive particles is adjusted such that the distance between the surface and the abrasive profile changes radially from the foot area to the head area, allowing for varying surface roughness by altering the material proportion along the flank height, enabling a variable surface roughness on the ground tooth flank.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a uniform layer of abrasive particles is applied to the tooth-shaped surface and the base body is connected to the carrier layer, then the manufacturing process is simple and consistent, but the surface roughness along the tooth height becomes uniform, which is not always desirable
Solution Approach 1:
The patent applies local quality by varying the amount of abrasive particles in different regions of the dressing roller. Specifically, the abrasive layer thickness or particle concentration is adjusted along the tooth height (from foot area to head area) to create different surface roughness characteristics in different zones. This allows the single dressing roller to produce variable surface roughness profiles on the grinding worm, meeting diverse surface quality requirements without changing the manufacturing process complexity.
2Ease of manufacture
If the abrasive profile is produced with equal material proportion along the flank height, then the manufacturing process is straightforward, but the resulting gear workpiece has uniform surface roughness across the tooth flank, which does not meet specific machining requirements
Solution Approach 1:
The patent implements parameter changes by modifying the material proportion of abrasive particles along the flank height of the dressing roller. The abrasive layer thickness, particle size distribution, or particle concentration is varied as a parameter function of position (from foot to head area). This creates a dressing roller with non-uniform abrasive distribution, which transfers variable surface roughness characteristics to the ground gear workpiece, achieving precise surface quality control while maintaining relatively simple manufacturing processes.
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 allows for the production of a dressing roller that can impart a variable surface roughness to the grinding worm, enabling the creation of gear-shaped workpieces with customized surface characteristics, meeting specific requirements for tooth flank machining.
Implementation Method 1
abrasive particles are distributed on said surface inside the negative mold and embedded, for example, in a layer of nickel; the material, here: nickel, that holds the abrasive particles forms a carrier layer for the abrasive particles
Implementation Method 2
Profiling of the base body provided with abrasive particles by removing external sections of the abrasive particles with a profiling tool
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a method for dressing a grinding worm using a dressing roller (1), in which the dressing roller (1) provided with an abrasive profile (2) is brought into engagement with the grinding worm, the abrasive profile (2) of the dressing roller (1 ) is tooth-shaped in radial section and extends radially (r) from a foot area (3) to a head area (4), the dressing roller (1) being produced by the steps of: a) producing a negative mold (5) with an inner surface (6); b) applying abrasive particles (7) to the surface (6) and fixing them, a carrier material forming a carrier layer (14) for the abrasive particles (7); c) producing a base body (8) of the dressing roller (1) and connecting it to the carrier layer (14); d) demoulding of the base body (8); e) profiling of the base body (8). In order to specifically influence the proportion of abrasive material used above the flank height, the invention provides that during the production of the negative mold (5) according to step a), this is provided with the surface (6) in such a way that the distance (x ) between the surface (6) and the abrasive profile (2) at least on a flank (12, 13) of the surface (6), measured in a radial section perpendicular to the surface (6), as you progress from the foot area (3) to the head area ( 4) changes.