Profile Grinding Wheel Chamfering for Burr-Free Gear Tooth Ends
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Solution Overview
Problem
The production of gears and profiles often results in burrs and sharp edges at the front ends, particularly when grinding into solid form without pre-processing, requiring manual rework and lacking a defined chamfering method.
Innovation Solution
A method using a dressable profile grinding wheel with a specific angle adjustment between the workpiece and grinding wheel axis, allowing for precise grinding of chamfers by changing the grinding wheel profile through dressing before grinding the chamfers, enabling controlled and defined chamfering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If grinding is carried out into solid form without pre-processing, then the toothing or profile can be produced directly, but burrs and sharp edges occur at the front ends requiring manual rework
Solution Approach 1:
The method applies preliminary chamfering action before the final grinding operation. By grinding chamfers at the axial ends during the grinding process itself (using the same grinding wheel after tooth grinding), the method prevents burr formation and prepares the surface in advance, eliminating the need for subsequent manual rework and ensuring consistent surface quality.
2Manufacturing precision
If manual chamfering is applied to remove burrs, then surface quality can be improved, but additional rework time and labor are required
Solution Approach 1:
The method merges the tooth grinding operation and the chamfering operation into a single integrated process. The same profile grinding wheel is used for both operations, and both are performed during the same setup and clamping of the workpiece. This eliminates the need for separate manual chamfering operations and reduces total processing time.
Solution Approach 2:
The profile grinding wheel is designed to perform multiple functions: it grinds the tooth profiles with precise geometry and also grinds the chamfers at the axial ends. This multi-functionality eliminates the need for separate tools or operations for chamfering, reducing both time and complexity.
3Manufacturing precision
If separate devices are used for chamfering, then defined chamfers can be applied, but device complexity increases
Solution Approach 1:
The profile grinding wheel serves dual purposes: it grinds the tooth profiles with precise geometry and also grinds the chamfers at the axial ends. This eliminates the need for separate chamfering devices or special tools, reducing device complexity while maintaining manufacturing precision through the controlled grinding process.
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
Enables efficient and precise removal of burrs and application of defined chamfers at the axial ends of gears and profiles, improving the grinding process by using the same profile grinding wheel for both tooth/profile grinding and chamfering, reducing manual rework and ensuring consistent geometry.
Implementation Method 1
grinding the tooth or profile gaps of the workpiece using the profile grinding wheel; and grinding chamfers in the area of the axial end of the tooth or profile gaps by means of the grinding wheel
Implementation Method 2
the profile of the grinding wheel is changed by a dressing process
Data Source
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AI summary
The invention relates to a method for grinding a toothing (1) of a workpiece (2) by means of a profile grinding wheel (3), wherein the workpiece (2) has an axis of rotation (a), wherein the grinding wheel (3) has an axis of rotation (b) and a centre (M) which lies on the axis of rotation (b) of the grinding wheel (3) and in the middle of the axial extent (e) of the grinding wheel (3), and wherein the workpiece (2) has an end face (7) at least in an axial end region (5, 6) of the toothing (1) or of the profile. In order to produce the axial ends of the toothing without burrs in a simple and precise manner, the invention provides that the grinding of the toothing (1) comprises the steps of: a) grinding the tooth gaps (4) of the workpiece (2) by means of the profile grinding wheel (3); b) grinding chamfers (9) in the region of the axial end (8) of the tooth gaps (4) by means of the grinding wheel (3), wherein the grinding wheel (3), at least temporarily during the grinding of the chamfers (9), takes up a position in which the grinding wheel (3) is arranged relative to the workpiece (2) such that an axial end (8) of the tooth gap (4) is in contact with the grinding wheel (3), wherein, in projection onto a plane that contains the axis of rotation (a) of the workpiece (2) and the centre (M) of the grinding wheel (3), an angle (δ) of between 20° and 70° is enclosed between the axis of rotation (a) of the workpiece (2) and the connecting line (RV) between the axial end of the tooth gap (8) and the centre (M).