Parallel Toothing and Deburring Cycle Time Reduction
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Solution Overview
Problem
Existing methods for producing toothings on workpieces require high mechanical engineering outlay and are not efficient in terms of productivity and cycle time.
Innovation Solution
The method involves simultaneous or parallel processing of reworking toothings on one end face while generating toothings on the other end face, using tools that can operate independently in time, allowing for immediate continuation of processing on the second end face after completing reworking on the first, and utilizing deburring and chamfering tools to remove burrs concurrently with the gearing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional sequential methods are used for producing toothings with deburring and chamfering, then manufacturing precision is improved, but productivity is reduced and cycle time increases
Solution Approach 1:
The invention applies preliminary action by performing deburring and chamfering operations simultaneously with the toothing generation process rather than sequentially. Multiple tools (toothing tool, deburring tool, and chamfering tool) operate concurrently on the workpiece, with deburring removing material in advance of chamfering, thereby eliminating waiting time and improving productivity while maintaining quality
Solution Approach 2:
The invention implements continuity of useful action by ensuring that all tools (toothing, deburring, and chamfering) operate continuously and simultaneously throughout the entire toothing generation process. The tools are positioned and synchronized so that useful work is performed at all times without idle periods, maximizing productivity while maintaining manufacturing precision through coordinated tool operations
2Productivity
If multiple tools are used for simultaneous toothing, deburring, and chamfering operations, then productivity is improved and cycle time is reduced, but device complexity increases
Solution Approach 1:
The invention merges multiple functions (toothing generation, deburring, and chamfering) into a single integrated machine tool setup. Multiple tools are mounted on the same machine and operate simultaneously on the workpiece, combining several manufacturing operations that would traditionally require separate machines or sequential processes, thereby improving productivity without proportionally increasing device complexity
Solution Approach 2:
The machine tool is designed with multi-functionality, capable of performing toothing generation, deburring, and chamfering operations with different tools mounted on the same device. This universal capability allows a single machine to replace multiple specialized machines, improving productivity while keeping device complexity manageable through standardized tooling and positioning mechanisms
3Device complexity
If sequential processing is used for toothing generation and post-processing, then device complexity is reduced, but loss of time increases and productivity decreases
Solution Approach 1:
The invention applies preliminary action by positioning and preparing multiple tools (deburring and chamfering) in advance on the same machine tool, so they can operate simultaneously with the toothing generation process. This eliminates the time loss associated with moving workpieces between machines or repositioning tools sequentially, reducing cycle time while maintaining manageable device complexity through coordinated tool setup
Data Source
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AI summary
In a method for producing toothed sections on workpieces, a toothed section is firstly produced by means of a first tool in the region of a first end face of a workpiece to be toothed. The produced toothed section is reworked on the peripheral face by means of at least one second tool in the region of the first end face, while the toothed section is further produced. If the toothed section is also produced in the region of the second end face by means of the first tool, the reworking in the region of the first end face is already completed, so the toothed section can also be reworked in the region of the second end face. Short cycle times are thereby achieved with a low machine-related outlay.