Tooth Groove Skiving with Phase Correction for Single-Tool Machining
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Solution Overview
Problem
Current tooth groove machining methods for external gears in synchronous cones require two types of gear cutting tools, leading to increased tool costs and machining errors due to tool exchange, and result in reduced cutting speed and longer tact times when using a single tool with a small intersection angle.
Innovation Solution
A tooth groove machining method and device that uses a single gear cutting tool by defining phase correction angles to maintain a sufficient intersection angle, allowing machining of both tooth side surfaces without changing the intersection angle, even when the taper angle is small.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two types of gear cutting tools are used for machining right and left tooth side surfaces, then machining precision can be maintained, but tool cost increases and machining time is extended due to tool exchange
Solution Approach 1:
The patent applies universality by enabling a single gear cutting tool to perform both right and left tooth side surface machining. The control device calculates and applies different phase correction angles for each surface, allowing one tool to replace two specialized tools while maintaining machining precision and eliminating tool exchange time.
Solution Approach 2:
The patent changes the phase correction angle parameter to adapt a single tool for different machining surfaces. By dynamically adjusting the phase correction angle based on the target surface (right or left tooth side), the system maintains manufacturing precision while using a universal tool, thus resolving the contradiction between precision and productivity.
2Productivity
If one type of gear cutting tool is used with 0° tool helix angle, then tool cost is reduced, but cutting speed decreases and tool wear increases due to small intersection angle
Solution Approach 1:
The patent changes the phase correction angle parameter to compensate for the 0° tool helix angle. By optimizing the phase correction angle, the system maintains a sufficient intersection angle between the tool and workpiece, ensuring adequate cutting speed and reduced tool wear while using a single versatile tool.
3Adaptability or versatility
If intersection angle is reduced to accommodate small taper angles, then tool versatility is improved, but cutting speed is reduced and tool wear increases
Solution Approach 1:
The patent dynamically adjusts the phase correction angle parameter based on the specific taper angle requirements. This parameter change allows the tool to adapt to different workpiece geometries while maintaining an optimal intersection angle, thereby preserving cutting speed and extending tool life despite the use of a single versatile tool.
Data Source
AI summary
A tooth groove machining method includes: defining a shift angle as a phase correction angle in skiving when shifting a reference point of a predetermined tooth groove of a workpiece in a circumferential direction of the workpiece; machining a first tooth side surface by the skiving with a gear cutting tool, by setting an intersection angle to a predetermined intersection angle, and by setting the phase correction angle to a first phase correction angle; and machining a second tooth side surface by the skiving with the same gear cutting tool as the gear cutting tool that machined the first tooth side surface, by setting the intersection angle to be the same with the predetermined intersection angle, and by setting the phase correction angle to a second phase correction angle different from the first phase correction angle.