Skiving Tool Orientation for Gear Chamfering
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Solution Overview
Problem
Current methods for producing chamfers on toothed workpieces are complex, requiring multiple steps and tools, and are limited by geometric restrictions, making it difficult to quickly produce left-hand and right-hand chamfers without creating interfering contours.
Innovation Solution
A device with a tool spindle holder that allows for the rotation of two toothed tools, one on each side of the workpiece, with adjustable azimuth and polar angles, enabling the production of chamfers on both sides of the workpiece without interfering contours, using a modified skiving process where the tool is rolled and moved relative to the workpiece along the x-axis, allowing for varied chamfer angles and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If forming chamfering is used to create chamfers on tooth face edges, then chamfering can be performed, but secondary burrs and material protrusions are created requiring additional removal steps
Solution Approach 1:
The patent replaces the forming chamfering method (which causes plastic deformation and requires secondary operations) with a skiving cutting method. The skiving tool with cutting edges mechanically removes material in a single operation, eliminating the need for subsequent burr removal steps and simplifying the overall manufacturing process.
Solution Approach 2:
The skiving process efficiently discards material in the form of continuous chips during the cutting operation. The tool removes excess material and creates the chamfer in one continuous action, recovering only the necessary material removal without creating unwanted protrusions that would need further processing.
2Ease of manufacture
If chamfer cutting with a deburring tool is used, then chamfering can be performed, but only shallow chamfer angles can be produced and clearance space is required below tooth root
Solution Approach 1:
The skiving tool is designed with a specific orientation where the tool axis is inclined at an angle α (5° to 45°) relative to the workpiece axis. This dynamic angular configuration allows the cutting edges to engage the tooth face edges at optimized angles, enabling the production of chamfers with a wide range of angles without requiring clearance space below the tooth root.
Solution Approach 2:
The patent changes the critical parameter of tool orientation by inclining the tool axis at angle α relative to the workpiece axis. This parameter modification fundamentally alters the cutting geometry, enabling deep chamfers with various angles to be produced without the geometric restrictions that limit conventional deburring tools.
3Manufacturing precision
If conventional gear hobbing followed by forming chamfering is used, then gear teeth can be cut and chamfered, but multiple individual steps with specialized tools are required
Solution Approach 1:
The patent merges the gear hobbing operation and the chamfering operation into a single integrated process. The skiving tool, used immediately after hobbing, performs both the cutting of gear teeth and the creation of chamfers on the tooth face edges in one continuous operation, eliminating the need for separate specialized tools and steps.
Solution Approach 2:
The skiving tool serves multiple functions: it cuts the gear teeth during the hobbing operation and subsequently creates chamfers on the tooth face edges. This multi-functional tool replaces the need for separate specialized chamfering tools, simplifying the manufacturing system and improving productivity while maintaining precision.
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 the rapid production of chamfers on toothed workpieces with flexible geometry, avoiding interfering contours and allowing for large helix angles, with minimal material removal and efficient machine utilization.
Implementation Method 1
a toothed tool (2) with tooth end faces (11, 31) serving as rake faces, which run approximately perpendicular to the tool axis (WZA), is rolled against the workpiece (1)
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The invention relates to a method for skiving machining of a toothed workpiece (1), wherein a toothed tool (2) rotating about a tool axis (WZA) slides in a contact zone (KZ) on the workpiece (1) rotating about a workpiece axis (WSA), wherein the workpiece axis (WSA) defines an x-direction and the perpendicular of the contact zone (KZ) to the workpiece axis (WSA) defines a z-direction, and the x-direction, a y-direction, and the z-direction form a right-angled co-ordinates system, wherein the tool axis (WZA) is pivoted about an azimuth angle φ>0° against the x-direction. Said method is characterised in that the tool axis (WZA) is also pivoted by a polar angle θ<90° against the z-direction, and a chamfer (30) is produced by means of the tool (2) on the toothed workpiece (1). The invention relates to a method by which in a simple manner a chamfer can be produced on a toothed workpiece which is subject to fewer geometric restrictions.