Threaded Gear Grinding for Corner Relief Without Tooth Breakage
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Solution Overview
Problem
In gear manufacturing, phase shift during meshing leads to high surface pressure and potential tooth breakage, requiring additional grinding steps with specialized tools, which reduces manufacturing efficiency.
Innovation Solution
A gear manufacturing apparatus and method that uses a threaded tool with spiral processing teeth to grind one corner portion of the gear workpiece, utilizing the termination tooth surface for corner portion grinding control, allowing for efficient formation of tooth surfaces without tooth breakage and eliminating the need for specialized tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional grinding with specialized tools is performed to form relief shapes at corner portions, then tooth breakage due to phase shift is prevented, but manufacturing efficiency deteriorates
Solution Approach 1:
The threaded tool is designed to perform multiple functions: it can perform both finishing grinding of the tooth surface and corner portion grinding to form relief shapes. By integrating corner portion grinding capability into the standard threaded tool, the patent eliminates the need for specialized corner grinding tools, thereby maintaining manufacturing efficiency while preventing tooth breakage
Solution Approach 2:
The patent combines the finishing operation and corner relief formation operation into a single grinding process using one threaded tool. The tool is configured with specific tooth surfaces that can contact the corner portions of the gear workpiece during meshing, allowing simultaneous or sequential formation of both the tooth surface and corner reliefs without requiring separate processing steps
2Manufacturing precision
If tool replacement or device relocation is performed for corner portion grinding, then precise relief shapes are formed, but manufacturing complexity increases
Solution Approach 1:
The threaded tool is designed with specific tooth surfaces capable of performing both standard finishing and corner relief grinding functions. This multi-functionality allows the same tool to achieve precise corner relief shapes without requiring tool replacement or relocation to different devices, thereby reducing processing complexity while maintaining precision
Solution Approach 2:
The threaded tool is pre-configured with specific tooth surface geometries that enable it to automatically contact and grind the corner portions of the gear workpiece during the normal meshing process. This preliminary configuration of the tool geometry allows precise corner relief formation to occur as part of the standard grinding operation, eliminating the need for additional positioning or setup 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
The solution effectively reduces tooth breakage at the meshing start by grinding only the necessary corner portions, enhancing manufacturing efficiency and tool longevity through the use of a single tool for all grinding operations.
Implementation Method 1
grind a gear workpiece including teeth formed on its outer circumferential surface, by meshing and rotating the gear workpiece and a threaded tool including one or more spiral processing teeth
Data Source
AI summary
A gear manufacturing apparatus configured to grind a gear workpiece including teeth formed on its outer circumferential surface, by meshing and rotating the gear workpiece and a threaded tool including one or more spiral processing teeth formed on an outer circumferential surface of a base portion of the tool, including: a control device configured to execute a corner portion grinding control in which one corner portion among four corners of each tooth surface of the gear workpiece is ground such that a termination, which is an edge of the processing tooth in a tooth trace direction, comes into contact with the gear workpiece, utilizing only a termination tooth surface in a one-side tooth surface of the processing tooth or the other-side tooth surface of the processing tooth, the termination tooth surface being set to include part of the termination and being one closed region.