Power Skiving Tool Geometry for Flat Polygonal Profiles
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Solution Overview
Problem
Existing methods for producing polygonal profiles, such as polygon turning, result in slightly convex surfaces and lower surface quality, failing to achieve the precision and flatness required for cost-effective mass production.
Innovation Solution
A power skiving tool with convexly rounded teeth and a specific configuration that allows for the production of almost completely flat surfaces by using a power skiving machining process, where the tool and workpiece rotate in opposite directions with a defined axis cross angle and translational movement, enabling the creation of regular convex polygon profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If polygon turning is used to produce polygonal profiles, then cost-effectiveness and productivity are improved, but surface quality and precision deteriorate with slightly convex surfaces
Solution Approach 1:
The invention changes the fundamental machining parameters by switching from polygon turning to power skiving process, and by using teeth with convexly rounded contours instead of traditional sharp-edged teeth. This parameter change enables the production of flat surfaces with polygonal profiles simultaneously, resolving the contradiction between productivity and surface quality.
Solution Approach 2:
The invention applies curvature to the tooth contours by using convexly rounded shapes instead of straight or sharp-edged geometries. This curvature in the tool tooth design directly produces flat surfaces on the workpiece while maintaining the polygonal profile, thereby improving surface quality without sacrificing productivity.
2Manufacturing precision
If conventional milling is used to produce flat surfaces on round workpieces, then surface quality is improved, but productivity and cost-effectiveness deteriorate
Solution Approach 1:
The invention changes the machining process parameters by adopting power skiving with specifically designed convexly rounded teeth, which enables simultaneous achievement of high surface quality and high productivity, overcoming the limitations of conventional milling.
Solution Approach 2:
The cutting tool is segmented into multiple teeth with convexly rounded contours, allowing simultaneous engagement of multiple cutting edges with the workpiece. This segmentation enables high material removal rates while maintaining surface quality, thus improving productivity without sacrificing precision.
3Ease of manufacture
If polygon turning is used, then cost savings are achieved, but harmful factors increase with crowned surfaces that do not meet precision requirements
Solution Approach 1:
The invention changes the tooth geometry parameters to convexly rounded contours and adopts power skiving process parameters, which eliminate the harmful crowned surface effect while maintaining cost-effectiveness through efficient mass production capability.
Solution Approach 2:
The invention converts the potential harm of crowned surfaces into a benefit by using convexly rounded tooth contours that produce flat surfaces. The rounded tooth geometry, which might seem to compromise precision, actually eliminates the crowned surface defect and produces the desired flat surfaces with polygonal profiles.
Data Source
AI summary
A power skiving tool comprising a shank that extends along a longitudinal axis of the tool, and a cutting head that is arranged at an end face of the shank. The cutting head comprises a plurality of circumferentially arranged teeth, wherein, when viewed in a cross-section orthogonal to the longitudinal axis, each of the teeth comprises a convexly rounded contour, which at a first end transitions either directly or via a first concave transition contour into the convexly rounded contour of a first adjacent tooth of the plurality of teeth and at a second end opposite the first end transitions either directly or via a second concave transition contour into the convexly rounded contour of a second adjacent tooth of the plurality of teeth. A width of each tooth of the plurality of teeth, measured in the cross-section as a distance between the first end and the second end, is greater than a height of the respective tooth, measured in the cross-section orthogonal to the width and centrally between the first end and the second end.