Tooth Surface Deviation Measurement for Gear Grinding Accuracy
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Solution Overview
Problem
Existing methods for measuring tooth surface deviation between a gear and a grinding tool are inaccurate, leading to reduced accuracy and forming capability in grinding tool formation and gear grinding processes.
Innovation Solution
A tooth surface deviation measuring apparatus and method that uses contact detecting means, rotational speed changing means, and a measuring device to accurately measure phase changes along the entire circumference of the gear, ensuring precise contact between the grinding tool and gear surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If all dresser teeth of the dresser gear are used to form the grinding tooth surface, then the forming capability is maximized, but the accuracy of the grinding tooth surface is reduced due to cumulative deviations
Solution Approach 1:
The invention segments the measurement and correction process by measuring deviations of individual dresser teeth separately and correcting each tooth's position independently. This allows the system to handle multiple teeth without cumulative error propagation, resolving the contradiction between using all teeth for high productivity while maintaining high accuracy through individual correction.
2Manufacturing precision
If only some dresser teeth are used to form the grinding tooth surface, then the accuracy is improved by avoiding cumulative deviations, but the forming capability is reduced
Solution Approach 1:
The invention implements feedback by measuring the actual deviation of each dresser tooth from its ideal position and using this information to correct the positioning or compensation parameters. This feedback mechanism enables the system to maintain high accuracy while utilizing all dresser teeth, thereby preserving forming capability without the trade-off.
3Device complexity
If conventional contact detection methods are used, then the device complexity is low, but the measurement precision of tooth surface deviation is insufficient
Solution Approach 1:
The invention introduces an intermediary measurement mechanism that detects contact between the grinding tool and dresser tooth surfaces through intermediate parameters (such as force, displacement, or acoustic signals). This intermediary approach enables high-precision deviation measurement while keeping the overall system relatively simple by using established sensing technologies rather than complex direct measurement systems.
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
This approach allows for highly accurate measurement and correction of tooth surface deviations, enhancing the accuracy of grinding tool formation and gear grinding, thereby increasing the forming capability of the dresser gear and improving the ground accuracy of workpiece gears.
Implementation Method 1
contact between a tooth surface of a tooth of a gear to be machined and a side surface of a grinding wheel screw is confirmed by an acoustic emission (AE) ultrasonic sensor
Data Source
AI summary
A device for measuring tooth surface deviation includes a contact detector that measures the deviation at the tooth surface of a dresser with respect to a grinding tooth surface formed on a helical grinding tooth of a grinding tool when the grinding tool and a dresser toothed wheel are rotated synchronously in a state in which the grinding tooth surface and the dresser tooth surface of the dresser toothed wheel can be brought into contact, and detects contact between the grinding tooth surface and the dresser tooth surface; and a controller that changes the speed of rotation of the dresser toothed wheel in such a way that the detection result of the contact detector comes within the range of contact determination data, and also measures the amount by which the grinding tool and the dresser toothed wheel have been changed in one revolution of the dresser toothed wheel.