Multilayer Gear Grindstone Structure for Higher Peripheral Speed
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Solution Overview
Problem
Conventional multilayer grindstones for gear grinding face limitations in achieving satisfactory grinding speed and efficiency due to differences in expansion between the rough and finish machining portions, leading to reduced peripheral speed and increased machining time, especially when these portions are fixed at their end surfaces and bonded at the outer peripheral portions.
Innovation Solution
The multilayer grindstone design includes a rough machining portion and a finish machining portion with separate cores that are fixed at their end surfaces but not bonded at the outer peripheral surfaces, allowing for independent operation and maintaining the same breaking strength and rotational speed as when used as single units, while the rough machining portion is typically a vitrified grindstone and the finish machining portion is a resinoid or abrasive-cloth laminated grindstone with higher elasticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the rough machining portion and finish machining portion are fixed at their entire end surfaces to each other, then the multilayer grindstone can perform machining operation at high speed, but the difference in expansion between the two portions causes the upper limit of peripheral speed to be lower, reducing grinding efficiency
Solution Approach 1:
The grindstone is divided into a rough machining portion and a finish machining portion that are not fixed to each other, allowing each portion to expand independently during rotation. This segmentation eliminates the expansion difference problem that limits peripheral speed in conventionally bonded multilayer grindstones.
Solution Approach 2:
The rough machining portion and finish machining portion are nested coaxially on the rotational axis, with each portion having its own core structure. This nested arrangement allows independent expansion while maintaining overall structural integrity and balanced rotation at high speeds.
2Strength
If the rough machining portion and finish machining portion are used as single units mounted on a spindle, then each maintains high breaking strength, but it is difficult to provide thread grooves that are exactly coincident in phase, increasing initial dressing operation time
Solution Approach 1:
The rough machining portion and finish machining portion are combined in a nested coaxial arrangement where both can rotate together as a unified structure. This merging allows thread grooves in both portions to be exactly coincident in phase, eliminating the need for time-consuming initial dressing operations while maintaining the high breaking strength of individual portions.
3Adaptability or versatility
If the finish machining portion has higher elasticity than the rough machining portion, then the finish machining portion can be displaced larger during rotation, but this causes the rough finishing portion to break at lower peripheral speed
Solution Approach 1:
The grindstone is segmented into independent rough machining and finish machining portions that are not bonded together. This allows the finish machining portion to have higher elasticity for better adaptability while the rough machining portion maintains its structural integrity and breaking strength, as each portion operates independently during rotation.
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 design enables higher machining efficiency by maintaining the same rotational speed and breaking strength as single units, reducing the time required for dressing operations, and allowing for higher peripheral speeds, thus enhancing the overall grinding performance and efficiency.
Implementation Method 1
there could be difference between the rough machining portion and the finish machining portion in expansion, wherein the difference could be caused due to the difference of elastic modulus or other physical characteristics
Data Source
AI summary
A gear-grinding multilayer grindstone includes a rough machining portion and a finish machining portion that are disposed adjacent to each other on a rotational axis. The rough machining portion includes a first core and a rough machining grindstone that is held on the first core. The finish machining portion includes a second core that is adjacent to the first core, and a finish machining grindstone that is held on the second core. The first core and the second core are fixed to each other, without the rough machining grindstone and the finish machining grindstone being fixed at least at outer peripheral portions thereof to each other.