Gear Toothing Rolling With Parallel Axes for Multi-Pitch Machining
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Solution Overview
Problem
Current gear machining methods are inefficient in reducing processing time, increasing accuracy, and allowing tools to be used for multiple pitches or diameters, as they require complex tools and multiple setups for different gear configurations.
Innovation Solution
A method where the tool and workpiece axes are parallel, with the tool and workpiece rotating in opposite directions, using a cutting edge contour that corresponds to the positive shape of the toothing, allowing for the production of circular arc teeth with adjustable parameters like tool radius and center distance, enabling the creation of gears with varying pitches and diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional polygon turning or fly-tooth milling is used, then gears can be produced with complex tool forms, but the tool requires significantly more teeth than necessary and cannot be used for different pitches or diameters
Solution Approach 1:
The tool is designed with a universal form that can produce different gear pitches and diameters by varying the rotational speeds of the tool and workpiece, eliminating the need for multiple specialized tools. The tool form corresponds to the positive shape of the gear to be produced, allowing it to function across multiple gear configurations.
Solution Approach 2:
The invention changes the operational parameters (rotational speeds of tool and workpiece) rather than the tool geometry itself to achieve different gear outputs. By adjusting the speed ratio between tool and workpiece, various pitches and diameters can be produced with the same tool.
2Productivity
If gear shaping with indexing is used, then a simpler tool form is achieved, but the machining time increases due to sequential tooth production
Solution Approach 1:
The invention achieves continuous tooth production through simultaneous rolling motion of the tool and workpiece, eliminating the intermittent indexing operations required in traditional gear shaping. The rolling contact ensures that all teeth are produced continuously in one machining pass, significantly reducing total machining time.
3Ease of operation
If polygon turning with angled axes is used, then peripheral gears can be produced, but the tool and workpiece axes must be at an angle throughout the entire machining process
Solution Approach 1:
Instead of using angled axes as in traditional polygon turning, the invention inverts the approach by using parallel axes for both tool and workpiece. The gear teeth are generated through the rolling motion of parallel axes, simplifying the setup and operation while maintaining machining efficiency.
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 processing time, increases accuracy, and allows for the production of gears with multiple pitches and diameters using a single tool setup, improving the efficiency and versatility of gear machining.
Implementation Method 1
the tool and the workpiece are driven in rotation in opposite directions to one another in order to roll on one another during the production of the gear
Data Source
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AI summary
The invention relates to a method for producing a gear, such as a splined or circular arc gear, on a workpiece using a tool comprising at least one tooth with a cutting edge having a contour that at least partially corresponds to the positive shape of the gear to be produced, wherein the tool axis and the workpiece axis are parallel to each other during gear production, and the tool and the workpiece are driven in opposite directions to roll against each other during gear production. The invention further relates to a combination of workpiece and tool, a machine tool, in particular a milling machine, for producing a gear, such as a splined or circular arc gear, on a workpiece, and the use of a tool for producing a gear, such as a splined or circular arc gear, on a workpiece.