Variable-Speed Gear Grinding for Quieter Tooth Flanks
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Solution Overview
Problem
Existing methods for hard-fine machining of gear toothing surfaces struggle to effectively influence noise behavior during operation, often requiring complex equipment and limited achievable effects.
Innovation Solution
The method involves using a grinding tool, such as a grinding worm, with a non-constant rotational speed during engagement with the toothing, either by varying the speed over the entire width or specific portions, and optionally adjusting the feed rate and tool displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional constant speed grinding is used, then the machining process is simple and stable, but the surface structure cannot be effectively optimized for noise reduction
Solution Approach 1:
The patent applies dynamics by transitioning from constant rotational speed to continuously variable rotational speed during the grinding process. The grinding tool's speed is dynamically adjusted according to a predetermined function, creating variable surface structures that reduce noise while maintaining process stability through electronic control.
Solution Approach 2:
The patent implements parameter changes by varying the rotational speed parameter of the grinding tool during engagement with the toothing. This speed variation, controlled by a predetermined function, modifies the surface structure of the tooth flanks to influence noise behavior without requiring complex mechanical modifications.
2Manufacturing precision
If eccentric tool movement or varying feed rate is used, then surface modification is achieved, but equipment complexity increases or effects are limited
Solution Approach 1:
The patent replaces complex mechanical systems (such as eccentric movement mechanisms or variable feed rate systems) with a simpler electronic control system that varies the rotational speed of the grinding tool. This substitution achieves the same surface modification effect with reduced mechanical complexity.
3Object-affected harmful factors
If special dressing of grinding tool is applied, then noise development is improved, but the process becomes more complex
Solution Approach 1:
The patent applies preliminary action by pre-defining the rotational speed variation function before the grinding process begins. This predetermined function guides the speed variations throughout engagement, achieving noise reduction through planned surface structure modification rather than complex tool dressing operations.
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 the generation of advantageous surface topographies with minimal additional effort, resulting in gears with improved noise behavior and reduced perceived noise during operation.
Implementation Method 1
the grinding tool is guided relative to the toothing during the machining in order to grind the toothing over its width
Data Source
AI summary
A method for rolling hard-fine machining of a toothing of a workpiece by a grinding tool, in which the grinding tool is mounted on a tool spindle and rotates while the grinding tool engages with the toothing. The grinding tool is guided relative to the toothing during machining to grind the toothing over its width. The grinding tool rotates at a non-constant rotational speed during its engagement with the toothing at least over a portion of the width. The rotational speed of the grinding tool during its engagement with the toothing has a constant basic value on which an additionally time-varying rotational speed function is superimposed, or the rotational speed of the grinding tool during its engagement with the toothing increases or decreases continuously or non-continuously over the entire width of the toothing or increases or decreases continuously or non-continuously over portions of the width of the toothing.