Sliding Collar Gear Machining With Skiving and Combination Tooling
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Solution Overview
Problem
Current methods for machining internally toothed gears and sliding sleeves are complex and costly, lacking a structurally simple and cost-effective solution for complete machining, particularly in producing roofs, backings, and locking grooves on the teeth.
Innovation Solution
A device comprising a first machine unit with a skiving tool for internal tooth formation and a second rotary tool spindle with a combination tool for sequential machining of left and right slopes, backings, and locking grooves, allowing for flexible ordering and efficient production using two machine units that can be controlled by a common controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate tools and machine units are used for machining different features (chamfers, backings, locking grooves), then machining precision and quality can be maintained, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separate machining functions (chamfering, backing, locking groove machining) into a single combination tool that can perform all these operations. This single tool integrates multiple cutting edges and machining capabilities that were previously required separate tools, thereby reducing device complexity while maintaining machining precision through a unified tool design.
Solution Approach 2:
The combination tool is designed with multi-functionality to perform various machining operations including chamfering, backing, and locking groove machining on gear teeth. This universal tool eliminates the need for multiple specialized tools and machine units, resolving the contradiction by providing all necessary functions in one integrated device that maintains precision across different operations.
2Device complexity
If sequential machining of chamfers, backings, and locking grooves is performed with one tool, then device complexity is reduced, but production time may increase
Solution Approach 1:
The combination tool is designed to perform chamfering, backing, and locking groove machining in continuous sequential operations without requiring tool changes or repositioning of workpieces between different machine units. The tool maintains continuous engagement with the workpiece, executing multiple machining functions in one setup, which reduces production time despite the sequential nature of the operations.
Solution Approach 2:
The combination tool performs preliminary machining actions for all features (chamfers, backings, locking grooves) in a single tool engagement with the workpiece. By preparing and machining all necessary features during one tool-spindle operation sequence, the system eliminates subsequent repositioning and tool change time, thereby maintaining productivity while reducing device complexity.
3Productivity
If two tool spindles are used for simultaneous chamfering of both tooth flanks, then production time is reduced, but device complexity and cost increase
Solution Approach 1:
The combination tool integrates multiple cutting edges that can machine both left and right chamfers on tooth flanks within a single tool engagement. Instead of requiring two separate tool spindles operating simultaneously, the combined tool consolidates these functions into one tool-spindle unit, reducing device complexity while maintaining efficient production through sequential chamfering operations.
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 cost-effective complete machining of sliding sleeves with reduced effort, allowing for flexible production of slopes, backings, and locking grooves in any order, with burrs removed during finishing steps, enhancing the efficiency and simplicity of the process.
Implementation Method 1
a toothless blank is given internal teeth by means of a skiving tool using a skiving process
Implementation Method 2
The combination tool has one or more chamfer cutting edges, backing cutting edges, and a locking groove cutting edge arrangement
Implementation Method 3
the cutting wheel having a plurality of cutting teeth, each forming a backing cutting edge
Implementation Method 4
The combination tool has one or more chamfer cutting edges, backing cutting edges, and a locking groove cutting edge arrangement
Data Source
Figure 1~2
Figure 3~6
Figure 7~8
AI summary
The invention relates to an apparatus for complete machining of sliding collars, comprising a first machine unit (1) having the first workpiece spindle (5), the first tool spindle (3), the second tool spindle (13) and a control device (20), wherein the first tool spindle (3) is equipped with a skiving tool (4) and the second tool spindle (13) is equipped with a tool (14) which has, on a free end, left and right chamfer cutting edges (25', 26') for producing the left and right chamfers on the end faces of the teeth of the working gear (6), at least one recess cutting edge (28'), arranged axially offset relative to the chamfer cutting edges (25', 26'), for producing the recesses in the tooth flanks of the teeth of the working gear (6), and at least one engagement groove cutting edge arrangement (29', 29''), arranged axially offset relative to the chamfer cutting edges (25', 26') and the recess cutting edge (28'), for producing engagement grooves in the tooth flanks of the teeth of the working gear (6), wherein the control device (20) is designed to control and to spatially relocate the drives of the tool and workpiece spindles (3, 13; 5, 15) such that, in a first machining step, a working gear (6) without teeth is toothed by means of the skiving tool (4), rotationally driven by the first tool spindle (3), in the skiving process and, in a second machining step, the chamfers, recesses and engagement grooves are produced successively by the tool (14) carried by the second tool spindle, without re-clamping the workpiece during the second machining step.