Skiving Tool Axis Alignment for Reduced Machine Complexity
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Solution Overview
Problem
Conventional skiving machines require multiple axes for complex machining processes, increasing machine complexity and costs, and there is a need to reduce production effort in producing gear tooth profiles.
Innovation Solution
A tool and method where the tool axis and workpiece axis are aligned at a crossing angle with an axial offset, allowing for a cutting speed component in the tooth space direction without the need for a pivot axis, enabling the skiving process to be performed with reduced machine axes and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional skiving machines use multiple axes for complex machining processes, then manufacturing precision can be maintained, but device complexity and production costs increase
Solution Approach 1:
The patent extracts and eliminates the pivot axis from the conventional five-axis skiving machine, reducing it to a three-axis machine. The cutting edge geometry of the tool is specifically designed to compensate for the removed degree of freedom, allowing the tool to generate the correct gear tooth profile without requiring the complex pivot axis movement.
Solution Approach 2:
The patent changes the geometric parameters of the cutting tool, specifically designing the cutting edge with specific angles and orientations that enable it to produce accurate gear profiles using only three axes. The tool geometry is optimized to create the necessary relative motion between tool and workpiece without requiring a pivot axis.
2Manufacturing precision
If conventional skiving machines use multiple axes, then gear profile accuracy is improved, but production costs increase
Solution Approach 1:
The patent removes the expensive pivot axis mechanism from the machine tool, thereby reducing equipment costs. The functionality previously provided by the pivot axis is replaced by carefully designed tool geometry and a simplified three-axis motion system, achieving the same manufacturing precision at lower cost.
Solution Approach 2:
The patent employs a specially designed cutting tool with optimized geometry that can be manufactured more economically. While the tool has specific geometric requirements, the overall system cost is reduced by eliminating the need for complex multi-axis machine tooling, making the process more economically viable.
3Adaptability or versatility
If a pivot axis is used in skiving machines, then complex gear geometries can be produced, but machine rigidity decreases
Solution Approach 1:
The patent removes the pivot axis that compromises machine rigidity. The complex gear geometries that previously required the pivot axis are now achieved through optimized three-axis motion control and specially designed tool geometry, maintaining versatility while improving structural stability and rigidity.
Solution Approach 2:
The patent replaces the mechanical pivot axis mechanism with a controlled motion system using three linear axes. The complex relative motion between tool and workpiece is achieved through coordinated movement along X, Y, and Z axes rather than through a physical pivot joint, eliminating the rigidity issues associated with mechanical pivots.
Data Source
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Figure 3a~3j
AI summary
The invention relates to a tool, a method and a machine for producing a gear profile (VP) by performing a coupled skiving motion between such a skiving tool (1) and the workpiece (2), wherein the tool (1) rotates about a tool rotation axis (WZ) and the workpiece (2) rotates about a workpiece rotation axis (WS).By designing the tool (1) as a crown gear, on the face of which a toothing (SP) with a cutting profile (5) is provided which in use maps the tooth profile (VP) on the workpiece (2), and by aligning the tool rotation axis (WZ) and the workpiece rotation axis (WS) to each other at an axis cross angle (∑) in the manner of the rotation axes of a bevel gear, and by providing an axis offset (a) between the workpiece rotation axis (WS) and the tool rotation axis (WZ) in order to effect a cutting speed component (vc) in the tooth gap direction (ZR) of the tooth profile (VP) to be produced between the workpiece (2) and the tool (1), a tooth profile on a workpiece can be produced by gear skiving with reduced manufacturing effort.