Variable Feed Rate Gear Grinding for Mesh Noise Reduction
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Solution Overview
Problem
Existing gear machining methods, such as grinding, often produce regular microscopic surface patterns on gear tooth flanks, leading to mesh noise when gears are in operation.
Innovation Solution
Varying the feed rate and/or shift rate of the grinding tool during the machining process to create an irregular surface pattern on gear tooth surfaces, which can be achieved by dividing the grinding stroke or shift length into segments and applying different feed or shift rates described by sinusoidal, ramped, or step functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a conventional grinding process is used with constant feed rate, then the machining process is simple and fast, but it produces regular microscopic surface patterns that cause mesh noise
Solution Approach 1:
The patent applies dynamics by varying the feed rate during the grinding process instead of using a constant feed rate. The feed rate is changed dynamically during different phases of the grinding stroke (infeed, crossfeed, and reciprocating motion), which creates irregular surface patterns that reduce mesh noise while maintaining process simplicity
Solution Approach 2:
The patent changes the feed rate parameter during the grinding process. By modifying the feed rate at different stages of the grinding stroke and using different feed rates for infeed versus crossfeed grinding, the process creates variable surface patterns that eliminate the harmful regular patterns causing mesh noise
2Object-affected harmful factors
If the feed rate is varied to create irregular surface patterns, then mesh noise is reduced, but the machining process becomes more complex
Solution Approach 1:
The grinding stroke is segmented into distinct phases (infeed phase and crossfeed phase), with each phase using a different feed rate strategy. This segmentation allows the process to create irregular surface patterns for noise reduction while maintaining efficient material removal rates in each phase, thus preserving overall productivity
3Object-affected harmful factors
If different feed rates are used for infeed and crossfeed grinding, then irregular surface patterns are created to reduce noise, but the control system becomes more complex
Solution Approach 1:
The patent implements periodic action by alternating between different feed rates during the reciprocating grinding strokes. The feed rate varies periodically according to the stroke phase (infeed vs. crossfeed), creating the desired irregular surface patterns while using a relatively simple control logic that switches between predetermined feed rate values
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 reduces mesh noise by creating an irregular spacing of grinding micro scratches, enhancing the operating characteristics of gears without increasing the time required for the machining process.
Implementation Method 1
The present invention is directed to a method of machining gears or other toothed articles wherein the workpiece feed rate and/or the tool shifting is varied so as to produce an irregular surface pattern on tooth surfaces
Data Source
AI summary
A method of machining gears or other toothed articles wherein the workpiece feed rate and/or the tool shifting is varied so as to produce an irregular surface pattern on tooth surfaces with a resulting reduction in mesh noise. The method is particularly applicable to grinding spur and/or helical gears with a grinding worm.