Pivot-Axis Chamfer Milling for Accurate Toothed Workpieces
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Solution Overview
Problem
Existing chamfering devices for toothed workpieces are not capable of producing chamfers with the required accuracy and speed, and often require re-chucking or changing tools for sequential machining steps.
Innovation Solution
A chamfering device with a milling spindle pivotably arranged on a pivot arm, featuring two parallel pivot axes for precise control of the end milling cutter's work angle, allowing for sequential chamfering without re-chucking or tool changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a milling spindle is arranged on a machining head with a single pivot axis, then the chamfering operation can be performed, but the accuracy and speed of chamfer production are insufficient
Solution Approach 1:
The single pivot axis is segmented into two separate pivot axes (first pivot axis and second pivot axis) that are arranged in parallel. The first pivot axis controls the work angle of the end milling cutter, while the second pivot axis controls the positioning of the milling spindle. This segmentation allows independent control of each function, improving chamfer accuracy without creating an unmanageably complex system.
Solution Approach 2:
The system employs dynamic positioning capabilities where the milling spindle can be quickly repositioned between the two parallel pivot axes during machining operations. This dynamic adjustment enables rapid switching between different chamfering positions and angles, significantly improving production speed while maintaining precision through controlled movement along the linear axis and pivot axes.
2Adaptability or versatility
If sequential machining steps require re-chucking or tool changes, then different operations can be performed, but productivity and efficiency are reduced
Solution Approach 1:
The machining head is designed as a universal platform that can accommodate multiple tools and perform multiple operations without requiring workpiece removal or re-chucking. The system can sequentially perform different machining steps (such as cutting, chamfering, and finishing) by positioning the milling spindle at different locations along the linear axis and adjusting the pivot axes, allowing one workpiece to remain clamped throughout the entire multi-step process.
Solution Approach 2:
The system enables continuous machining operations by eliminating interruptions for re-chucking or tool changes. The workpiece remains continuously clamped and processed through multiple sequential operations, with the milling spindle moving continuously between positions and the pivot axes adjusting angles without breaking the machining flow. This continuity significantly improves productivity while maintaining versatility for different machining steps.
3Manufacturing precision
If the work angle of the end milling cutter cannot be precisely controlled, then the setup is simpler, but the chamfer quality and precision are compromised
Solution Approach 1:
The control of work angle is segmented from the overall spindle positioning by introducing a dedicated first pivot axis that specifically controls the tilt angle of the end milling cutter relative to the workpiece edge. This separate control mechanism allows precise adjustment of the chamfer angle independent of the spindle's linear positioning, achieving high chamfer precision through specialized angular control.
Solution Approach 2:
The system incorporates feedback mechanisms through the coordinated control of the linear axis and two pivot axes, allowing real-time adjustment and verification of the work angle. The controller monitors the positions of all three axes and makes corrective adjustments to maintain the precise chamfer angle required for high-quality finishing, ensuring consistent precision throughout the machining process.
Data Source
AI summary
Device for chamfer machining of a toothed workpiece, wherein the device comprises at least one workpiece spindle having a rotatably mounted workpiece holder for holding the workpiece, and a machining head that is movable relative to the workpiece spindle via at least one linear axis, wherein at least one tool spindle having a rotatably mounted tool holder for holding at least one tool for machining a workpiece held in the workpiece holder is provided on the machining head, and wherein a milling spindle having a rotatably mounted milling cutter holder for holding an end milling cutter for chamfer machining an edge of a toothing of the workpiece held in the workpiece holder is provided on the machining head, wherein the work angle of an end milling cutter held in the milling cutter holder relative to the edge of the toothing can be set via a first pivot axis.