Threaded Grinding Wheel Design for Face Gear Precision
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Solution Overview
Problem
There is a lack of methods for manufacturing a threaded grinding wheel with specific specifications to accurately grind face gears, as existing technologies do not consider the necessary specifications for such tools.
Innovation Solution
A method involving the formation of a threaded tool that increases in diameter from axial ends to the center, utilizing a virtual pinion, virtual gear, and virtual internal gear to create a threaded grinding wheel with appropriate specifications for accurate grinding of face gears, allowing point contact and improved grinding efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a threaded grinding wheel is used to grind face gears, then grinding capability is provided, but the machining accuracy is insufficient due to lack of proper specification considerations
Solution Approach 1:
The patent introduces a virtual gear as an intermediary element in the specification setting process. The virtual gear serves as a mediator between the pinion and the threaded grinding wheel, allowing indirect determination of the grinding wheel specifications through virtual meshing relationships rather than direct complex geometric calculations
Solution Approach 2:
The patent transforms the complex geometric specification problem into a parameter-based solution by defining specific parameters for the virtual gear (number of teeth, module, pressure angle) and using these parameters to systematically determine the threaded grinding wheel specifications through standardized relationships
2Productivity
If conventional grinding methods are used, then existing tool specifications can be applied, but the grinding speed and efficiency are insufficient for high-precision face gear machining
Solution Approach 1:
The patent performs preliminary specification setting of the threaded grinding wheel before actual machining by using virtual gear meshing relationships. This preliminary action ensures that the grinding wheel is properly configured for both high-speed operation and precision machining, avoiding trial-and-error adjustments during actual grinding
3Manufacturing precision
If the threaded grinding wheel specifications are not properly considered, then manufacturing is simpler, but the tool cannot accurately grind the face gear tooth surfaces
Solution Approach 1:
The patent creates a virtual copy of the gear meshing relationship through the virtual gear model. This virtual copying allows the specification design to be performed through simulated meshing conditions rather than requiring complex direct geometric modeling, simplifying the manufacturing process while ensuring accuracy
Data Source
AI summary
A method for manufacturing a screw-shaped tool for grinding a face gear with high precision. The tool is formed in such a manner that the diameter thereof gradually increases from an axial end to an intermediate section in the axial direction, and is used for cutting a face gear. The method includes setting up, on the basis of a prescribed pinion which is to mesh with the face gear to be machined, a virtual gear that is to mesh with the prescribed pinion, and has a greater number of teeth than the prescribed pinion; setting up, on the basis of the virtual gear, a virtual inner gear which has the same number of teeth as the virtual gear, said teeth being on the inside; and setting up, on the basis of the virtual inner gear, a screw-shaped grindstone having various elements that are used for cutting the virtual inner gear.