Gear Tooth Flank Chamfering With Parallel-Axis Rolling Cutting
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Solution Overview
Problem
Existing methods for supplementary tooth forming, such as roller pressure deburring, often result in secondary burrs on tooth flanks and end faces, which are difficult to remove, especially after hardening, and do not provide satisfactory quality for subsequent machining processes.
Innovation Solution
A method where two tooth arrangement rotational axes are parallel, with a first relative movement along the workpiece rotational axis and a second relative movement shifting the tool's envelope position orthogonal to the workpiece rotational axis, allowing for material removal in slices to form a chamfer without parallel cutting, enabling flexible and precise machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If roller pressure deburring is used to form chamfers, then the method is simple and does not require rotational driving, but secondary burrs are created on tooth flanks and end faces that are difficult to remove
Solution Approach 1:
The patent replaces the pressing mechanism of roller pressure deburring with a cutting mechanism. The chamfering tool uses cutting edges that rotate in rolling coupling with the workpiece tooth arrangement, removing material through cutting rather than plastic deformation. This substitution eliminates the generation of secondary burrs while maintaining operational simplicity.
Solution Approach 2:
The patent changes the fundamental machining parameter from pressing force to cutting motion. By transitioning from a pressing process to a cutting process with controlled material removal, the harmful effect of secondary burr generation is eliminated while achieving the desired chamfer geometry.
2Ease of operation
If roller pressure deburring is used to form chamfers, then the operation is simple, but secondary burrs on end faces require additional deburring steps
Solution Approach 1:
The cutting-based chamfering method replaces the pressing mechanism, eliminating secondary burr generation on end faces. This single operation achieves both chamfer formation and surface cleaning, removing the need for additional deburring equipment and steps.
Solution Approach 2:
The patent combines the chamfering operation with the burr removal function into a single cutting process. The cutting edges simultaneously form the chamfer geometry and remove any burrs that might form, merging multiple functions into one operation.
3Manufacturing precision
If material removal is performed to form chamfers, then tooth edge quality is improved, but machining time increases
Solution Approach 1:
The rolling coupling between the chamfering tool and workpiece enables continuous cutting action without interruption. The rotational movement maintains constant contact between cutting edges and workpiece surface, ensuring continuous material removal and efficient chamfer formation without idle periods.
Solution Approach 2:
The patent employs dynamic rolling coupling where both the chamfering tool and workpiece rotate simultaneously. This dynamic interaction creates efficient cutting conditions with continuous chip removal, maintaining high material removal rates while ensuring precise chamfer geometry.
4Manufacturing precision
If cutting chamfering is performed with geometrically defined cutting edges, then precise chamfer geometry is achieved, but the process becomes more complex than pressing methods
Solution Approach 1:
The patent replaces complex pressing mechanisms with a simpler cutting system based on rolling coupling. The geometrically defined cutting edges are achieved through the rotational motion and engagement geometry, eliminating the need for complex pressing device mechanisms while maintaining 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 method effectively removes material from tooth flanks and end faces to create chamfers with desired profiles, reducing secondary burrs and improving the quality of tooth edges, allowing for efficient and flexible machining of tooth edges and flanks, including hard-to-reach areas.
Implementation Method 1
the tooth arrangements rotate about their respective tooth arrangement rotational axes in rolling coupling
Data Source
AI summary
The invention relates to a method for machining a tooth edge, formed between a tooth flank and an end face of a workpiece tooth arrangement, by means of a tool tooth arrangement, in which method the tooth arrangements rotate about their respective tooth arrangement rotational axes in mutual rolling coupling. According to the invention, it is provided that the two tooth arrangement rotational axes be substantially parallel to each other and the machining be carried out over a plurality of workpiece rotations, wherein a first relative movement, parallel to the workpiece rotational axis, between the workpiece tooth arrangement and the tool tooth arrangement is carried out, and the position of the envelope of the tool tooth rolling positions is shifted relative to the engagement position of said envelope with the tooth flank of the workpiece tooth arrangement in the plane orthogonal to the workpiece rotational axis, transversely to the profile of the workpiece tooth arrangement, by means of a second relative movement, which is varied in particular according to the movement state of the first relative movement.