Segmented Skiving Cutter for Internal Gear Precision
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Solution Overview
Problem
Manufacturers of internal gears face challenges in achieving precision processing and extending the service life of skiving cutters used for manufacturing internal gears.
Innovation Solution
A skiving cutter with a circular cross-sectional base and segmented cutting edges, where the reference cutting edge has the largest axis-cutting edge distance, and other edges have gradually smaller distances, along with varying helix angles and cutting edge configurations, to prevent unintended cutting and enhance processing accuracy and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the skiving cutter uses multiple cutting edge portions to process internal gears, then productivity is improved, but manufacturing precision deteriorates due to unintended cutting in non-target regions
Solution Approach 1:
The cutting edge portions are segmented into multiple discrete cutting edges along the tooth trace direction. Each segmented cutting edge is independently positioned and controlled, allowing precise engagement with the workpiece tooth groove while preventing unintended cutting in non-target regions. This segmentation enables multiple cutting edges to work simultaneously without interfering with each other's precision.
Solution Approach 2:
Each segmented cutting edge is designed with specific local characteristics including varying axis-cutting edge distances and helix angles tailored to its position. The reference cutting edge has the largest axis-cutting edge distance, while other cutting edges have progressively smaller distances. This local differentiation ensures that each cutting edge engages the workpiece at the correct position and angle, maintaining precision while enabling multi-edge productivity.
2Productivity
If the skiving cutter operates for extended periods to improve productivity, then service life becomes a limiting factor, but prolonged operation increases wear on cutting edges
Solution Approach 1:
The cutting edge is divided into multiple segmented cutting edges that can wear independently. When some segmented cutting edges become worn, others remain effective, allowing the cutter to continue operation. This segmentation extends the overall service life of the cutter by providing redundant cutting capability across multiple edges.
Solution Approach 2:
The cutter design allows selective use of different segmented cutting edges during operation. As some edges wear, the system can effectively 'discard' those edges and continue using remaining sharp edges, maximizing the utilization of the cutter's cutting capability throughout its service life.
3Device complexity
If cutting edges are positioned closer to the axis to reduce cutter size, then device complexity is reduced, but cutting precision deteriorates due to increased load on each edge
Solution Approach 1:
By segmenting the cutting edge into multiple edges distributed along the tooth trace, the load is divided among multiple cutting points rather than concentrated on a single edge. This allows the cutter to maintain larger axis-cutting edge distances for better precision while distributing mechanical load across multiple segmented edges, reducing stress on individual edges.
Solution Approach 2:
The cutter employs more cutting edges than the minimum single edge would provide. This excessive action of using multiple cutting edges allows each edge to operate with reduced load and improved positioning accuracy, as the cumulative cutting action of multiple edges achieves the required material removal while maintaining precision.
Data Source
AI summary
A skiving cutter includes a cutting edge portion in which a tooth trace extends in a direction inclined with respect to an axis of a base. The cutting edge portion is segmented into a plurality of segmented cutting edges by cutting edge grooves extending in a direction intersecting the tooth trace. One of the plurality of segmented cutting edges forms a reference cutting edge. Among the plurality of segmented cutting edges constituting the cutting edge portion, the reference cutting edge has the largest axis-cutting edge distance which is a distance from the axis to the outer circumferential cutting edge of the segmented cutting edge, and the remaining one or more segmented cutting edges have gradually smaller axis-cutting edge distances as a distance from the reference cutting edge to each of the remaining cutting edges increases. A helix angle is different according to positions of the plurality of segmented cutting edges.