Grinding Worm Dressing Roller for Variable Tooth Roughness
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Solution Overview
Problem
Existing dressing rollers used for grinding worms produce uniform surface roughness along the tooth height, which is not suitable for applications requiring variable surface roughness, as they maintain a constant material proportion along the flank height, limiting the ability to achieve desired surface finishes in gear manufacturing.
Innovation Solution
A method to produce a dressing roller with a variable abrasive profile by adjusting the distance between the base body's profiled surface and the abrasive layer along the flank height, allowing for different material proportions and surface areas across the tooth height, enabling the creation of a dressing tool with a targeted variable material content for specific surface roughness requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a constant distance is maintained between the profiled surface and abrasive profile, then uniform material proportion is achieved along the flank height, but variable surface roughness cannot be produced
Solution Approach 1:
The patent applies local quality by varying the distance between the profiled surface and abrasive profile at different locations along the flank height. Specifically, the distance is increased on one flank and decreased on the other flank, creating different material proportions in different regions of the dressing roller. This enables the dressing roller to produce variable surface roughness on the ground tooth flank across its height, while maintaining controlled and precise material distribution through the defined distance variations.
2Adaptability or versatility
If the distance between profiled surface and abrasive profile is varied, then variable surface roughness can be achieved, but uniform material distribution is compromised
Solution Approach 1:
The patent applies asymmetry by creating an asymmetric distance distribution between the profiled surface and abrasive profile. The distance is increased on one flank of the tooth-shaped surface and decreased on the other flank, rather than maintaining symmetry or uniformity. This asymmetric configuration enables the dressing roller to produce different surface roughness characteristics on different sides, providing versatility for various surface finish requirements while maintaining precise control over material proportion through the defined asymmetric distance variations.
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 the production of grinding worms with variable surface roughness along the tooth height, allowing for customized surface finishes on gear-shaped workpieces, accommodating diverse manufacturing needs by varying the material proportion and surface roughness along the flank height.
Implementation Method 1
a precisely ground steel body is coated with a layer of abrasive particles, usually in the form of diamond grains, in a galvanic process
Data Source
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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 in order to profile its helical grinding profile, the dressing roller ( 1) is produced by the steps: a) producing a base body (5), the base body (5) being provided with a profiled surface (6) which is at least partially tooth-shaped in radial section, for receiving a layer of abrasive particles (7), b) arranging a layer of abrasive particles (7) on the surface (6) of the base body (5), c) profiling the base body (4) provided with abrasive particles (7) by using a profiling tool (8) to shape external sections (9) of the Abrasive particles (7) are removed so that the abrasive profile (2) of the dressing roller (1) results. In order to specifically influence the proportion of abrasive material used above the flank height, the invention provides that the profiled surface (6) is produced according to step a) in such a way that the distance (x) between the surface (6) and the abrasive profile (2) on a flank (10, 11) of the tooth-shaped surface (6), measured in a radial section perpendicular to the profiled surface (6), changes as you progress from the foot area (3) to the head area (4).