Variable Tooth Flank Modification in Continuous Gear Machining
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Solution Overview
Problem
Current methods for reducing gear noise in electromobility, particularly tonality issues, are inefficient and not highly productive, as they either require complex discontinuous processes or only provide uniform flank modifications that offer limited noise reduction.
Innovation Solution
A continuously rolling manufacturing process using tools with individually different tool profile geometries to create variable tooth flank modifications on gear teeth, allowing for cost-effective and high-productivity noise reduction by breaking tonality patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If discontinuous profile grinding is used to create variable flank modifications, then noise reduction is improved, but device complexity and productivity are worsened
Solution Approach 1:
The tool is divided into multiple tool teeth with different tool profile geometries along its length. Each tool tooth creates a different flank modification on successive gear teeth, enabling variable modifications without discontinuous processing. This segmentation of the tool geometry allows noise reduction while maintaining continuous high-productivity manufacturing.
Solution Approach 2:
The patent applies dynamic variation to the tool profile geometry along its length, creating a gradient of modifications rather than static uniform geometry. This dynamic approach allows the tool to impart different modifications (e.g., tip relief, lead modification, crowning) at different positions, reducing tonality while maintaining continuous operation and high productivity.
2Productivity
If continuously generating manufacturing processes are used for high productivity, then productivity is improved, but noise reduction capability is worsened due to uniform flank modifications
Solution Approach 1:
Different sections of the tool profile along its length are given different geometries, so that local variations in tool geometry create local variations in the flank modifications on gear teeth. This local quality approach allows continuous processing while achieving variable modifications that reduce noise and tonality.
Solution Approach 2:
The tool profile parameters (such as radius, angle, or shape) are varied along the length of the tool, creating a gradient of modifications. This parameter change enables the continuous generating process to produce different flank modifications on successive teeth, thereby reducing gear noise while maintaining high productivity.
3Ease of manufacture
If uniform flank modifications are applied to all gear teeth, then manufacturing simplicity is improved, but noise reduction is worsened due to tonality
Solution Approach 1:
The tool is segmented into multiple teeth with different profile geometries, allowing variable modifications to be applied automatically during continuous operation. This maintains manufacturing simplicity from the operator's perspective while achieving the complex variable geometry needed to reduce tonality.
Data Source
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AI summary
The invention relates to a method for producing tooth flank modifications on toothing of workpieces, in which the workpiece and a tool are moved relative to one another and, as a result, material is removed from the tooth flank (3) of the workpiece. Different tooth flank modifications are generated on teeth (1) of the workpiece by means of a continuously rolling manufacturing process, by the tool comprising individually different tool profile geometries which generate the different tooth flank modifications on the teeth (1) of the workpiece. The tool can be a dresser with variable profile in order to provide, with dressable tools, individually different tool profile geometries.