Profile Grinding Wheel Chamfering for Burr-Free Tooth Ends
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In the manufacturing of toothings and profiles, burr formation and sharp edges often occur at the face ends of the toothing after grinding, particularly when gear teeth or profiles are ground directly into the solid without pre-machining, requiring manual reworking.
Innovation Solution
A method using a profile grinding wheel to grind both the tooth or profile gaps and apply defined chamfers to the axial ends of the toothing or profile, with the grinding wheel positioned to allow an axial end of the tooth or profile gap to contact it at a specific angle, typically between 20° and 70°, enabling precise and controlled chamfering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If gear teeth or profiles are ground directly into the solid without pre-machining, then manufacturing precision is improved, but burr formation and sharp edges occur at the face ends requiring manual reworking
Solution Approach 1:
The invention combines two previously separate operations (grinding the toothing and chamfering the face ends) into a single grinding process. The profile grinding wheel is designed with multiple working surfaces that can simultaneously grind the toothing profiles and create defined chamfers at the axial ends, eliminating the need for manual reworking while maintaining precision
Solution Approach 2:
The profile grinding wheel is designed to perform multiple functions: it can grind the toothing profiles with high precision and simultaneously create defined chamfers at the axial ends of the tooth spaces. This multi-functional tool eliminates the need for separate chamfering operations or manual intervention
2Manufacturing precision
If face chamfers are machined in a separate operation, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The invention merges the toothing grinding operation and the chamfering operation into a single process step using one profile grinding wheel. The wheel is designed with specific profiles that allow it to simultaneously create both the precise toothing and the defined chamfers, reducing device complexity while maintaining precision
Solution Approach 2:
The profile grinding wheel serves as a universal tool that performs both toothing grinding and chamfering functions. By designing the wheel with appropriate profiles and angles, it can accomplish multiple machining tasks in one operation, simplifying the overall manufacturing system
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 method allows for the simple and precise removal of burrs and the application of defined chamfers, improving the finish and quality of the toothing or profile without the need for manual reworking, especially suitable for large workpieces and small batch production.
Implementation Method 1
Grinding of the tooth or profile gaps of the workpiece by means of the profile grinding wheel; Grinding of chamfers in the region of the axial end of the tooth or profile gaps by means of the grinding wheel
Data Source
AI summary
A method for grinding a toothing of a workpiece by a profile grinding wheel. The workpiece each have an axis of rotation. The grinding wheel has a center which lies on the axis of rotation of the grinding wheel and in the middle of the axial extent of the grinding wheel. The workpiece has an end face at least in an axial end region of the toothing or of the profile. The method includes the steps of: a) grinding the tooth gaps by the profile grinding wheel; b) grinding chamfers in the region of the axial end of the tooth gaps by the grinding wheel. The grinding wheel takes up a position in which it is arranged so that an axial end of the tooth gap is in contact with the grinding wheel. In projection onto a plane that contains the axis of rotation of the workpiece and the center of the grinding wheel, an angle of between 20° and 70° is enclosed between the axis of rotation of the workpiece and the connecting line between the axial end of the tooth gap and the center.