Internal Gear Deburring with Alternating-Direction Cutting Inserts
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Solution Overview
Problem
Existing methods for deburring workpieces with internal teeth produced by skiving are inefficient and require additional mechanical processing steps, as they fail to effectively remove burrs without complex tool configurations and multiple passes.
Innovation Solution
A deburring method using a non-rotating tool with two diametrically opposite cutting inserts that rotate the workpiece in alternating directions to efficiently deburr both tooth flanks, ensuring no additional mechanical processing is needed, with the tool's cutting edges aligned to minimize idle strokes and maximize deburring efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional deburring methods are used on workpieces with internal teeth, then burrs can be removed, but additional mechanical processing steps and complex tool configurations are required
Solution Approach 1:
The deburring tool is segmented into two diametrically opposed cutting inserts, each responsible for deburring one flank of the internal teeth. This segmentation allows simultaneous engagement with both flanks during rotation, eliminating the need for tool repositioning and reducing processing steps while maintaining manageable tool complexity
Solution Approach 2:
The patent combines multiple deburring functions into a single tool by positioning two cutting inserts at diametrically opposite locations. This merging allows both tooth flanks to be deburred in one operation during a single workpiece rotation, significantly improving productivity without requiring multiple tools or complex tool changes
2Reliability
If multiple processing passes are used to deburr internal teeth, then complete burr removal is achieved, but processing time increases
Solution Approach 1:
The two cutting inserts are positioned to continuously engage with both flanks of the internal teeth during a single workpiece rotation. This continuous action ensures complete burr removal on both flanks simultaneously, eliminating idle time between passes and achieving reliable deburring in one operation rather than multiple sequential passes
Solution Approach 2:
The cutting inserts are pre-positioned at diametrically opposite locations on the tool, prepared in advance to engage both flanks simultaneously. This preliminary configuration ensures that when the workpiece rotates, both flanks are deburred in one continuous motion without requiring intermediate tool repositioning or additional processing time
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 provides a particularly efficient and reliable deburring process that eliminates the need for further mechanical processing, reducing operational complexity and enhancing productivity by ensuring complete removal of burrs in a single tool pass.
Implementation Method 1
deburring of tooth flanks of internal gearing with the non-rotating first cutting insert
Data Source
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Figure 6
AI summary
A workpiece (2), namely a gear with an inner toothing, is deburred using a deburring tool (1) which has two cutting plates (12, 13) in that the workpiece (2) is first rotated in a first rotating direction, wherein tooth flanks (7) of the inner toothing (3) of the workpiece (2) are deburred by means of the first cutting plate (12), and other tooth flanks (6) of the inner toothing (3) are deburred by means of the second cutting plate (13) in a later machining phase in which the workpiece (2) is rotated in the opposite direction.