Grinding Worm Overlapping Zones for Profiled Gear Production

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Solution Overview

Problem

Existing grinding worm technologies face limitations in producing three-dimensionally modified tooth flanks with minimal residual deviations and high wear, leading to inefficient use of worm width and long profiling times, especially in large series production.

Innovation Solution

A grinding worm with overlapping roughing and finishing zones, combined with a profiling gear having differently shaped flank modifications, allows for flexible workpiece geometry adaptation and reduced profiling time by minimizing the transition zone and optimizing the use of worm width.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the grinding worm is divided into separate roughing and finishing zones, then wear resistance is improved, but the usable grinding worm width is reduced due to the transition zone

Engineering Contradiction:

Improvewear resistanceVSAvoidusable grinding worm width

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The patent merges the roughing and finishing zones by allowing them to overlap axially, eliminating the separate transition zone between them. This combining approach maintains the functional benefits of zone separation for wear management while maximizing the usable width of the grinding worm through overlapping engagement zones.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If a fixed profile roll is used for profiling, then manufacturing simplicity is improved, but the loss in usable grinding worm width at the transition between zones increases

Engineering Contradiction:

Improveprofiling simplicityVSAvoidusable grinding worm width

Core Design Contradiction:

Ease of manufactureVSLength of moving object

Solution Approach 1:

The patent replaces the fixed profile roll with a form roll that enables continuous path control, allowing the profiling process to dynamically adjust and minimize the transition zone between roughing and finishing areas. This dynamic approach reduces the width loss while maintaining ease of manufacture through standardized profiling equipment.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If radiussed form rolls with continuous path control are used for profiling, then manufacturing flexibility is improved, but profiling time increases

Engineering Contradiction:

Improveworkpiece geometry flexibilityVSAvoidprofiling time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent segments the grinding worm into distinct roughing and finishing zones that can be profiled separately and then overlap during operation. This segmentation allows for optimized profiling of each zone independently, reducing total profiling time while maintaining the ability to produce complex three-dimensional tooth flank modifications through the overlapping engagement.

Inventive Principle:

Principle #1Segmentation

4Device complexity

If the same grinding worm zone is used for both rough and finish grinding, then device simplicity is improved, but manufacturing precision deteriorates due to high wear during rough grinding

Engineering Contradiction:

Improvegrinding zone configurationVSAvoidfinish grinding accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent applies local quality by creating distinct roughing and finishing zones with different functional characteristics on the same grinding worm. The roughing zone is designed for high material removal with appropriate abrasives, while the finishing zone is optimized for precision with different abrasive characteristics. The overlapping axial arrangement allows each zone to perform its specialized function while maximizing overall worm utilization.

Inventive Principle:

Principle #3Local quality

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 solution enables efficient production of three-dimensionally modified tooth flanks with reduced residual deviations and wear, allowing for flexible workpiece geometry changes without altering the profiling gear, thus improving production efficiency in large series manufacturing.

Implementation Method 1

The grinding worm flank geometry derives from the conjugate reproduction of the tooth geometry of the profiling gear which, instead of the workpiece, is brought into mesh with the grinding worm

Methodology Applied

Scientific EffectConjugate reproduction:

Implementation Method 2

using an abrasive grain coated profiling gear

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS8113915B2Grinding worm, profiling gear and process for the profiling of the grinding worm

Publication Date: 2012.02.14 REISHAUER AG

AI summary

A grinding worm for the continuous generation grinding of a work piece is provided with mutually overlapping rough grinding and finish grinding zones arranged along the worm's axis, the finished grinding zone being provided with a three-dimensionally modified flank geometry having a width related design.