Tooth Flank Geometry Modification for Direct Contact Pattern Milling
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Solution Overview
Problem
Conventional methods for producing gearing on workpieces require post-processing to achieve desired contact patterns, which is costly and inefficient, especially when using single-purpose gear-forming machines.
Innovation Solution
A method for generating control data on numerically controlled machine tools with at least 5 axes allows for the direct creation of tooth flanks with desired contact patterns through milling, eliminating the need for post-processing by modifying the tooth flank geometry based on specified contact pattern areas and parameters before generating control data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional single-purpose gear-forming machines are used to produce gearing on workpieces, then the tooth flanks can be machined with standard tools, but post-processing is required to achieve desired contact patterns, increasing production cost and time
Solution Approach 1:
The invention modifies the tooth flank geometry in advance during the control data generation phase, before the actual machining process. By calculating and adjusting the tooth flank geometry to account for expected deformation and contact pattern requirements, the system eliminates the need for post-processing operations such as lapping or grinding, thereby improving productivity while maintaining ease of manufacture
Solution Approach 2:
The invention changes the geometric parameters of the tooth flank during the control data generation process. By adjusting parameters such as tooth flank relief, contact pattern area, and geometry modifications based on specified parameters, the system directly machines the desired contact pattern into the workpiece, eliminating costly and time-consuming post-processing steps
2Manufacturing precision
If post-processing operations such as lapping or grinding are performed to optimize contact patterns, then the desired contact pattern can be achieved, but the production cost and processing time increase significantly
Solution Approach 1:
The system performs preliminary modification of the tooth flank geometry during control data generation, calculating the exact geometry needed to achieve the desired contact pattern after machining. This preliminary action eliminates the need for time-consuming post-processing operations while maintaining high manufacturing precision for the contact pattern
Solution Approach 2:
The invention replaces mechanical post-processing operations (lapping, grinding) with a computational approach. By using computer-aided calculation and control data generation that directly accounts for contact pattern requirements, the system substitutes complex mechanical post-processing with efficient numerical computation and direct machining, significantly reducing time loss while maintaining precision
3Ease of manufacture
If conventional methods machine tooth flanks with standard tools, then the basic tooth geometry can be created, but the contact pattern requires additional reworking on another machine tool
Solution Approach 1:
The invention merges the tooth flank machining and contact pattern formation operations into a single machining process. By modifying the control data to include contact pattern geometry adjustments, the system combines what were previously separate operations (basic tooth geometry machining and contact pattern optimization) into one unified process, reducing device complexity and improving ease of operation
Solution Approach 2:
The invention enables standard universal machine tools to perform multiple functions: creating the basic tooth geometry and forming the desired contact pattern in a single operation. This multi-functionality eliminates the need for specialized single-purpose gear-forming machines and separate post-processing equipment, thereby reducing device complexity while maintaining ease of operation
Data Source
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Figure 3~4C
Figure 5A~5B
AI summary
The method involves predetermining tooth flank geometry, and determining a tooth bearing region (3) on the tooth flank geometry. Parameters e.g. reset positions and reset parameters (4a-4h), are determined for changing the tooth flank geometry. Control data is generated based on the tooth flank geometry that is changed based on the determined tooth bearing region and the determined parameters. The tooth bearing region is determined such that a tooth bearing with desired size, design and position is resulted during load-free rolling of a tooth flank. Independent claims are also included for the following: (1) a device for generating control data for manufacturing a work-piece (2) a device for generating control data for creating a tooth flank (3) a numerically controlled universal machine tool for milled processing of a work-piece (4) a computer program product comprising a computer-readable medium and a computer program to perform a method for generating control data for creating a tooth flank.