Multi-Spindle Profile Grinding for One-Setup Surface Machining
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Solution Overview
Problem
Existing grinding machines lack the capability to economically produce workpieces with complex geometry to high precision, particularly when transitioning between different machining surfaces like cycloidal gear profiles and cylindrical or flat surfaces.
Innovation Solution
The grinding machine is enhanced with a T-shaped configuration of grinding spindles, including a third spindle for cylindrical or flat surface grinding, along with a measuring element, allowing for precise machining of complex profiles, cylindrical, and flat surfaces in a single setting without re-clamping, forming a cross-shaped structure for enhanced precision and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple different grinding machines are used to machine different surfaces (profile, cylindrical, flat), then each surface can be machined with appropriate specialized tools, but the workpiece must be re-clamped and transported between machines, reducing manufacturing precision and increasing production time
Solution Approach 1:
The patent combines multiple grinding spindles (first, second, and third grinding spindles with different grinding tools) onto a single machine bed, allowing profile grinding, cylindrical surface grinding, and flat surface grinding to be performed on one machine. This eliminates the need to transport and re-clamp the workpiece between multiple machines, thereby maintaining high geometric accuracy while consolidating device complexity into a single integrated system.
Solution Approach 2:
The machine is designed with multi-functional capability to perform different grinding operations (profile grinding, cylindrical surface grinding, flat surface grinding) using different grinding spindles and tools on the same machine bed. This universal design allows one machine to replace multiple specialized machines, improving manufacturing precision by eliminating re-clamping operations while managing device complexity through integrated functionality.
2Productivity
If the workpiece is re-clamped and transported between different grinding machines, then different specialized grinding tools can be used for different surfaces, but this process reduces productivity and increases manufacturing time
Solution Approach 1:
By merging multiple grinding spindles and tools onto a single machine bed, the patent enables all grinding operations (profile, cylindrical, flat surfaces) to be performed in one setup. This eliminates the time-consuming processes of transporting and re-clamping the workpiece between machines, significantly improving productivity while reducing setup and transport time.
Solution Approach 2:
The machine is configured with all necessary grinding spindles and tools ready in advance on the same machine bed. The workpiece is clamped once and all subsequent grinding operations are performed without additional setup or transport, eliminating preliminary actions that would otherwise be required between different machines.
3Adaptability or versatility
If only profile grinding tools are used on a swivel head, then the machine can machine non-planar profiles, but it cannot machine cylindrical or flat surfaces with high precision in the same setup
Solution Approach 1:
The swivel head is equipped with multiple grinding spindles carrying different types of grinding tools: profile grinding tools for non-planar contours, cylindrical grinding tools for cylindrical surfaces, and flat grinding tools for flat surfaces. This multi-functional configuration allows the machine to perform all types of grinding operations on a single workpiece setup, enhancing adaptability while maintaining high manufacturing precision for all surface types.
Solution Approach 2:
Different grinding tools for diverse machining operations are merged onto a single swivel head, enabling the machine to switch between profile grinding, cylindrical surface grinding, and flat surface grinding without changing equipment. This integration maintains versatility for different surface types while ensuring high precision through consistent setup and eliminating re-clamping operations.
Data Source
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AI summary
The invention relates to a grinding machine (1) for grinding a profile, comprising a machine bed (2), wherein a machining device (3) is arranged on the machine bed (2), the machining device (3) comprising a swivel head (4) which carries a first grinding spindle (5) with a first grinding tool (6), in particular a roughing grinding tool, and a second grinding spindle (7) with a second grinding tool (8), in particular a finishing grinding tool, wherein a workpiece carrier designed as a rotary table (9) is arranged on the machine bed (2). In order to be able to produce workpieces with complex geometries economically and with high precision, the invention provides that the swivel head (4) further carries at least a third grinding spindle (10) with a third grinding tool (11), wherein the swivel axis (A) of the swivel head (4) is horizontally oriented and the axis of rotation (B) of the rotary table (9) is vertically oriented.