Skiving Tool Orientation for End Face Gearing
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Solution Overview
Problem
Current methods for producing end face gearing on workpieces are inefficient due to high investment costs, long processing times, and quality issues related to concentricity, as they require specialized gear cutting machines and multiple reclamping, which increases throughput times and reduces machine utilization.
Innovation Solution
The method involves using a skiving tool positioned at an angle greater than 0° and less than 20° in the X-Z plane, allowing for the production of end face teeth on a conventional turn-mill center, enabling simultaneous machining operations like turning, milling, and drilling without the need for a separate gear cutting machine, thus achieving short processing and throughput times with high concentricity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous processes like hobbing are used to produce end face gearing, then processing time is reduced, but high investment costs and need for special gear cutting machines are required
Solution Approach 1:
The patent applies universality by enabling a conventional turn-mill center to perform end face gearing production through skiving, allowing the machine to handle multiple machining operations (turning, milling, drilling, and skiving) without requiring dedicated gear cutting equipment. This multi-functional approach eliminates the need for special machines while maintaining continuous processing capabilities
Solution Approach 2:
The patent changes the parameter of tool positioning by arranging the skiving tool at a specific angle (greater than 0° and less than 20°) in the X-Z plane relative to the workpiece axis. This parameter modification enables conventional machines to achieve continuous gear generation that was previously only possible with specialized equipment
2Manufacturing precision
If multiple machining operations are performed on separate machines, then each operation can be optimized, but throughput time increases due to reclamping
Solution Approach 1:
The patent merges multiple machining operations (turning, milling, drilling, and skiving) into a single processing step on one turn-mill center. By combining these operations and maintaining workpiece clamping throughout, the patent eliminates reclamping time and ensures consistent concentricity across all features
Solution Approach 2:
The patent maintains continuous useful action by performing all machining operations without releasing or reclamping the workpiece. The workpiece remains securely clamped while the tool changes or repositions, ensuring uninterrupted processing and eliminating idle time associated with reclamping operations
3Adaptability or versatility
If intermittent indexing processes are used to produce face gearing, then flexibility is maintained, but processing time increases significantly
Solution Approach 1:
The patent transitions from static intermittent indexing to dynamic continuous skiving. The skiving tool rotates continuously with the workpiece while maintaining a controlled feed motion, creating a dynamic cutting action that generates gear teeth in one continuous operation rather than through repeated indexing steps
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 approach results in short processing and throughput times, excellent concentricity, and reduced investment costs by allowing end face teeth production on a conventional turn-mill center, preventing unwanted collisions and maintaining workpiece clamping throughout multiple machining operations.
Implementation Method 1
a skiving tool (5) is used in order to produce the end face toothing (8) on the face (6) of the workpiece (4)
Data Source
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AI summary
The method involves generating a front surface toothing on the front surface of the work piece. The front surface toothing is formed by hob peeling. The front surface is formed ring-shaped or planar, on which the front surface toothing is generated. The feed direction of the hob peeling tool (5) encloses an angle with the rotational axis of the hob peeling tool during the generation of the front surface toothing, where the angle lies between 15 degrees and 25 degrees.