Toothing Machining with Variable Tool Path for Collision Avoidance
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Solution Overview
Problem
Conventional toothing machining methods face challenges in achieving flexible and rapid machining, particularly when dealing with workpieces that have interfering contours close to the toothing, which can limit the axis intersection angle and result in longer machining times and potential collisions.
Innovation Solution
The method involves a two-step machining process where the first process produces the predominant flank geometry with conventional axial feeding, and a second process uses a changed movement path, including radial or tangential movements, to complete the flank geometry without full overtravel, allowing for higher axis intersection angles and avoiding collisions with interfering contours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional skiving with fixed axis intersection angle is used, then machining can be performed with simple movement control, but the tool center must perform full overtravel which increases machining time and may collide with interfering contours
Solution Approach 1:
The patent applies dynamics by making the axis intersection angle variable during the machining process. The toothing machine dynamically adjusts the angle between the tool axis and workpiece axis from an initial angle α1 to a final angle α2 during the machining operation. This dynamic adjustment allows the tool center to follow an optimized path that reduces overtravel distance while avoiding interfering contours, thereby decreasing machining time without requiring overly complex movement control
Solution Approach 2:
The patent implements parameter changes by varying the axis intersection angle as a controllable parameter during machining. The control system modifies this geometric parameter in real-time, transitioning from a fixed angle approach to a variable angle approach. This parameter change enables the tool to maintain optimal engagement with the workpiece while reducing the total travel distance and avoiding collisions with interfering contours
2Speed
If the axis intersection angle is increased to reduce overtravel, then machining speed improves, but the tool may collide with interfering contours on the workpiece
Solution Approach 1:
The patent uses dynamics to continuously adjust the axis intersection angle during the machining process. By transitioning from an initial angle α1 to a final angle α2, the system dynamically optimizes the tool path to achieve higher effective cutting speeds while simultaneously maintaining safe clearance from interfering contours. The dynamic adjustment ensures that speed improvements do not compromise collision avoidance
Solution Approach 2:
The patent implements feedback control by continuously monitoring the tool position and workpiece geometry during machining. The control system uses this feedback information to adjust the axis intersection angle in real-time, ensuring that the tool maintains an optimal trajectory that maximizes cutting speed while preventing collisions with interfering contours. The feedback mechanism allows the system to adapt to the specific workpiece geometry and avoid obstacles
3Manufacturing precision
If full overtravel is performed to complete flank geometry, then uniform toothing depth is achieved, but machining time increases and interfering contours are at risk of collision
Solution Approach 1:
The patent applies dynamics by varying the axis intersection angle during the machining process to optimize the tool path. This dynamic approach allows the tool to achieve uniform toothing depth through a more efficient trajectory that minimizes overtravel distance. By adjusting the angle from α1 to α2, the system maintains precision while reducing the time spent on non-productive overtravel movements and avoiding interfering contours
Data Source
AI summary
The invention relates to a method for machining a toothing (2) having an axis of rotation (C), in which a machining tool (4), which is rotationally driven about its axis of rotation (B), removes material from the toothing while executing a relative motion between the machining tool and toothing to generate a flank geometry of the toothing, which has been predefined over the full width of the toothing, in a machining operation, wherein the predefined flank geometry matches a motion control that defines a motion path of the tool center with respect to the toothing axis of rotation, said motion control having a defined, non-vanishing axial advancement with a defined advancing motion between machining tool and toothing, wherein in a first machining process, the relative motion is only executed for generating a part, more particularly a significant part (5), of the flank geometry according to this motion control, while a further part, more particularly the remaining part (6), of the flank geometry is generated in a second machining process, in which the distance between the tool center and the toothing axis of rotation with respect to the fixed motion path changes in a manner wherein the tool center moves away from the toothing, and in which the change to the machining operation caused thereby is counteracted by an additionally executed change in motion of the relative motion with respect to the motion control of the first machining process.