Involute Profile Milling Tool for Gear Flank Precision
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Solution Overview
Problem
Existing methods for profile milling of tooth flanks require a large number of specialized concave milling tools, leading to high costs and limited universal usability, as they need to closely approximate the tooth flank profile, resulting in restricted application and increased tooling expenses.
Innovation Solution
The use of a milling tool with a milling profile that has at least a partially involute course, allowing for section-wise milling with reduced profile deviations and enabling universal applicability by approximating any convex tooth flank shape with a smaller number of sections, and using a finger-shaped end mill for profile milling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a concave milling tool with a milling profile closely approximating the tooth flank profile is used, then manufacturing precision of the tooth flank is improved, but device complexity and the number of required milling tools increase
Solution Approach 1:
The patent applies a universal milling tool with a standard involute milling profile that can machine different tooth flank profiles by varying the setting angle, rather than requiring specialized concave milling tools for each tooth profile. This multi-functional approach reduces the number of tools needed while maintaining manufacturing precision through angular adjustment.
Solution Approach 2:
The patent changes the parameter of the milling tool's setting angle relative to the workpiece to adapt the standard involute milling profile to different tooth flank profiles. By adjusting the setting angle, the same tool can accurately machine various tooth geometries without requiring multiple specialized tools.
2Manufacturing precision
If multiple specialized concave milling tools are used to accurately machine different tooth flanks, then manufacturing precision is improved, but loss of substance increases due to undercuts
Solution Approach 1:
The universal milling tool with standard involute profile and adjustable setting angle eliminates the need for multiple specialized concave tools, thereby reducing excessive material removal. The angular adjustment capability allows the tool to accurately machine different tooth profiles without creating undercuts that would require material addition for compensation.
Solution Approach 2:
Instead of adapting the milling tool profile to match each tooth flank profile (traditional approach), the patent inverts the approach by using a standard involute milling profile and adapting it to different tooth profiles through angular adjustment. This inversion eliminates the undercut problem associated with concave tools.
3Device complexity
If a standard involute milling tool is used for section-wise milling, then device complexity is reduced and universal applicability is improved, but manufacturing precision may deteriorate due to profile deviations
Solution Approach 1:
The standard involute milling tool with adjustable setting angle achieves universal applicability for different tooth profiles while maintaining manufacturing precision. The angular adjustment compensates for profile deviations, allowing the standard tool to accurately machine various tooth geometries without requiring complex specialized designs.
Solution Approach 2:
By changing the setting angle parameter of the standard involute milling tool, the patent maintains manufacturing precision across different tooth profiles. The angular adjustment optimizes the cutting path and contact points, compensating for profile deviations and ensuring accurate tooth flank machining.
4Productivity
If section-wise milling with a standard milling tool is used, then productivity is improved by reducing the number of tools, but manufacturing precision may be compromised due to the need for multiple positioning operations
Solution Approach 1:
The patent uses parameter changes in the setting angle to maintain manufacturing precision during section-wise milling with a standard tool. The angular adjustment optimizes each cutting section, compensating for positioning variations and ensuring consistent profile accuracy across multiple operations, thereby maintaining productivity without sacrificing precision.
Data Source
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AI summary
The invention relates to a method and to a device (1) for profile-milling at least one tooth face (4) of a tooth (3) from a workpiece (2), with a workpiece (2), a milling tool (5) having a concave milling profile (8) that deviates at least partially from the tooth face (4) to be milled, with a tool holder (6) that holds the milling tool (5) and can move the same at least in three degrees of freedom (x, y, z), and with a controller (7) connected to the tool holder (6), said controller being connecting to the tool holder (6) between at least two milling sections (A1, A2) of the tooth face (4) for positioning the milling tool (5) on the workpiece (2). In order to create advantageous conditions, it is proposed for the milling tool (5) to have a milling profile (8) with an involute progression (10) at least in some areas.