Narrow Diamond Dressing Wheel for Gear Tool Flank Correction
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Solution Overview
Problem
Conventional dressing tools for fine machining of gear wheels and other components face limitations in achieving high-precision machining with optimal correction options, as they require specialized dressing wheels for each tool shape and are restricted by the width of the dressing wheel, which limits flank line corrections and adaptability.
Innovation Solution
A dressing wheel with a minimized thickness, typically up to 1.2 mm, made of diamond material, allowing for a narrow design that can be freely moved along the tooth flanks of the tool to be dressed, enabling precise control of tooth shape and flank corrections without the need for specialized wheels for each tool shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional dressing wheel with width corresponding to the tool width is used, then the entire width of tooth flanks can be swept during one revolution, but the freedom of movement along the tooth flanks is restricted and specialized wheels are needed for each tool shape
Solution Approach 1:
The invention divides the dressing wheel into two distinct components: a narrow dressing wheel (width 0.5-2mm) that provides freedom of movement, and a support structure that carries it. This segmentation allows the narrow wheel to move freely along the tooth flanks while the support structure provides stability and enables tool-specific adaptation through positioning rather than wheel redesign.
Solution Approach 2:
The narrow dressing wheel is designed as a universal component that can be used for dressing different tool shapes and sizes. By combining this single narrow wheel with adjustable support structures and positioning mechanisms, the system can adapt to various tool geometries without requiring specialized wheels for each tool type, thereby achieving multi-functionality.
2Ease of operation
If the dressing wheel width is reduced to increase freedom of movement, then flexibility along tooth flanks improves, but the ability to sweep the entire tooth flank width during one revolution is lost
Solution Approach 1:
The invention employs dynamic positioning of the narrow dressing wheel along the tooth flanks during the dressing process. The wheel is fed in the X-direction (radially inward) and can be positioned at different locations along the tooth flanks, allowing it to sweep the entire width over multiple passes while maintaining freedom of movement. This dynamic approach combines the benefits of narrow wheel mobility with complete flank coverage.
Solution Approach 2:
The support structure and positioning mechanisms are pre-configured to enable systematic coverage of the entire tooth flank width. By planning the dressing path and positioning in advance, the system ensures that the narrow wheel will cover the complete flank area through controlled movements, maintaining productivity despite the reduced wheel width.
3Adaptability or versatility
If a narrow dressing wheel is used to enable free movement, then adaptability and freedom of movement improve, but the structural strength and stability of the wheel may be compromised
Solution Approach 1:
The invention introduces a support structure as an intermediary between the narrow dressing wheel and the main tool holder. This support structure carries the narrow wheel and provides the necessary structural strength and stability, allowing the wheel itself to remain narrow and flexible while the support system ensures adequate mechanical strength during operation.
4Manufacturing precision
If specialized dressing wheels are used for each tool shape to maintain precision, then manufacturing precision is improved, but device complexity and production costs increase
Solution Approach 1:
The narrow dressing wheel is designed as a universal component that maintains manufacturing precision through controlled positioning and movement rather than through tool-specific wheel geometry. The support structure and positioning mechanisms enable the same narrow wheel to accurately dress different tool shapes by adjusting its position and path, eliminating the need for multiple specialized wheels while preserving precision.
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 approach reduces machining and production costs, enhances dresser service life, and allows for flexible machining of various tool shapes with improved precision and freedom of movement, eliminating the need for tool-specific dressing wheels and enabling independent machining of individual tooth flanks.
Implementation Method 1
a dressing wheel (A), in particular a diamond dressing wheel, made of a diamond material, at least in the area of its teeth (Z) which come into contact with the tool (1) to be dressed
Data Source
Figure 1~4
AI summary
The wheel (A) has a dressing tooth (Z) in contact with a tool to be dressed. The wheel is made of diamond material e.g. polycrystalline diamond, where thickness (D) of the wheel is limited to maximum of 1.2 millimeters in an area of the tooth. A chamfer is formed at a cutting edge of the tooth. A chamfer is formed at a cutting edge of the tooth. The wheel has disk which are glued on one another in fixed manner. Indentations (N) of the disks are arranged to be offset. An independent claim is also included for a dressing tool comprisign a carrier.