Skiving Cutter Geometry for Precision Gear Machining
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Solution Overview
Problem
Current gear machining technologies face challenges in achieving high precision and efficiency, particularly in strain wave gearing devices, where skiving methods result in significant tooth profile errors due to variations in cutter production and machining parameters, leading to increased manufacturing costs and reduced precision.
Innovation Solution
A gear machining apparatus with a skiving mechanism that positions the work and pinion type cutter on skewing axes, rotating the work synchronously while feeding the cutter in the direction of the gear tooth trace, featuring a tooth surface with an involute region, addendum, and dedendum regions, where the ratios of cutter to work tooth numbers are optimized to achieve precise machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If skiving method is used to machine internal gear, then machining time is reduced and productivity is improved, but machining precision deteriorates due to tooth profile errors
Solution Approach 1:
The patent changes the geometric parameters of the cutter tooth surface, specifically defining the involute region, addendum region, and dedendum region with specific mathematical relationships. The involute curve is defined with base circle radius rb, and the tooth surface is constructed with specific helix angles and lead angles, transforming the cutter geometry to achieve both high productivity and precision in skiving operations.
2Manufacturing precision
If multiple parameters are defined for skiving machining, then machining precision can be improved, but device complexity and difficulty of operation increase
Solution Approach 1:
The patent creates a universal cutter design where a single cutter with specifically defined tooth surface geometry can machine internal gears with different tooth numbers. The cutter incorporates an involute region, addendum region, and dedendum region that work together to generate accurate tooth profiles across multiple gear configurations, reducing the need for multiple specialized cutters and complex parameter settings.
3Manufacturing precision
If gear shaper is used to machine internal gear with high precision, then manufacturing precision is improved, but machining time increases and productivity decreases
Solution Approach 1:
The patent replaces the traditional gear shaper mechanical system with a skiving mechanism that uses a rotating cutter with specifically designed tooth surface geometry. Instead of the complex reciprocating motion of a gear shaper, the invention uses continuous rotational cutting with controlled feed, substituting a simpler mechanical system that achieves both precision and high productivity through optimized cutter geometry and cutting parameters.
Data Source
AI summary
A gear machining apparatus includes a skiving mechanism positioning a work to be machined and a pinion type cutter on axes skewing from each other, the skiving mechanism rotating the work at a predetermined position and feeding the cutter while rotating in a direction of a tooth trace of a gear to be formed at the work synchronously to the rotation of the work for producing the gear from the work. The cutter includes a tooth surface which is formed with an involute region having an involute curve in an area including a pitch circle in a tooth depth direction, an addendum region continuously formed from the involute region to an addendum, and a dedendum region continuously formed from the involute region to a dedendum the addendum region and the dedendum region being shaped in a configuration different from the involute region.