Power Skiving Cutter Geometry for Tooth Flank Smoothing
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Solution Overview
Problem
Existing skiving cutters fail to effectively reduce the surface roughness of tooth flanks on toothed workpieces, particularly in materials like tempering steel and nitriding steel with tensile strength below 1350 N/mm2, due to their cutting edges' small rounding radius which leads to inadequate smoothing.
Innovation Solution
A circular skiving cutter with machining teeth having a larger rounding radius than conventional cutters, allowing the machining edges to engage in a non-cutting motion that pushes roughness peaks into adjacent valleys, thereby smoothing the surface without metal removal, suitable for both internal and external toothings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional skiving cutters with small rounding radius are used, then cutting action is effective for material removal, but surface roughness reduction is insufficient
Solution Approach 1:
The patent applies parameter changes by increasing the rounding radius of the machining edges from conventional small values to at least 50 micrometers. This parameter modification transforms the cutting action into a smoothing action, allowing the machining edges to push roughness peaks into valleys without removing material, thereby significantly reducing surface roughness on tempering and nitriding steels.
2Manufacturing precision
If larger rounding radius is used for machining edges, then smoothing effect is improved, but material removal capability is reduced
Solution Approach 1:
The patent inverts the conventional approach by using a rounding radius that is larger than the penetration depth, which is the opposite of traditional cutting tools where the radius is smaller. This inversion causes the machining edges to push material peaks into valleys rather than cutting away material, achieving smoothing without sacrificing the rolling motion effectiveness for the specific application of finishing tooth flanks.
3Manufacturing precision
If non-cutting motion is used for smoothing, then surface roughness is reduced, but machining time increases
Solution Approach 1:
The patent merges the cutting and smoothing functions into a single operation by using machining edges with rounding radius of at least 50 micrometers that perform both material engagement and surface smoothing in one pass. The controlled penetration depth ensures that the same rolling motion that engages the teeth also smooths the surfaces, eliminating the need for separate smoothing operations and reducing total machining time.
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
The method significantly reduces surface roughness by using machining edges with a radius greater than 50 micrometers, ensuring a non-cutting action that effectively smooths tooth flanks without cutting, enhancing the finish on tempering and nitriding steels.
Implementation Method 1
The machining edges have a non-cutting effect. They push sections of the structures that form the roughness and protrude beyond a smoothing plane into adjacent regions that lie below the smoothing plane.
Data Source
AI summary
The invention relates to a method and a device for finishing toothed workpieces (2) using a tool (1) which is designed in the form of a power skiving cut-ter and is rotated by a tool spindle (17) and which has machining teeth (7) that mesh with tooth gaps (6) of the workpiece (2) in a rolling movement, said workpiece being supported by a workpiece spindle (15), which is arranged in a skewed manner relative to the tool rotational axis (4) and is driven synchronously thereto, such that machining edges (8) of the machining teeth (7) machine the tooth flanks (9) of the teeth (5) of the workpiece (2) in the direction of the tooth flank extension. According to the invention, the tool is used such that the machining edges (8) machine the tooth flanks (9) so as to only grind same without removing chips, wherein for this purpose the rounding radius of the machining edges (8) is greater than the chip thickness or cutting depth (E).