Vibration-Assisted Generating Grinding for Low-Noise Gear Flanks
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Solution Overview
Problem
Existing gear manufacturing processes, particularly continuous generating grinding, result in undesirable regular structures on gear tooth flanks, leading to noise issues during gear operation.
Innovation Solution
A method involving oscillating movements superimposed on the rotation of gear-shaped workpieces during machining, using a clamping device with a vibration generator to excite resonant vibrations, thereby modifying the meshing between the workpiece and the tool to reduce or eliminate regular structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If continuous generating grinding is used for hard finishing of gear tooth flanks, then manufacturing precision and surface quality are improved, but regular structures such as grinding grooves form on the tooth flanks leading to noise issues
Solution Approach 1:
The patent applies mechanical vibration by superimposing an oscillating movement on the gear-shaped workpiece during generating machining. This vibration modifies the meshing between the workpiece and tool, preventing the formation of regular grinding grooves on the tooth flanks, thereby reducing noise while maintaining surface quality
Solution Approach 2:
The patent implements periodic action through the oscillating movement of the workpiece during machining. This periodic oscillation interrupts the continuous contact between the grinding tool and workpiece, creating a non-uniform grinding pattern that eliminates regular structures and reduces noise generation
2Object-generated harmful factors
If additional polishing or honing processes are added downstream to eliminate regular structures, then noise is reduced, but manufacturing cost increases
Solution Approach 1:
The patent applies preliminary action by incorporating the oscillating movement directly into the generating machining process itself. This prevents the formation of regular structures during the primary machining operation, eliminating the need for subsequent polishing or honing processes and reducing overall process complexity
3Object-generated harmful factors
If Low Noise Shifting (LNS) with coupled rotation angles during dressing is used, then noise behavior is improved, but process complexity increases and not all noise-critical applications are covered
Solution Approach 1:
The patent uses mechanical vibration of the workpiece during machining as a more direct and effective approach compared to LNS. This vibration method modifies the meshing pattern fundamentally, providing better noise reduction for noise-critical applications while avoiding the complexity of coupling rotation angles during dressing
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
The method effectively reduces the formation of regular structures such as grinding grooves, leading to improved surface quality, reduced noise, and potential for increased process efficiency by allowing higher intensity grinding operations.
Implementation Method 1
a vibration generator (410) integrated into the clamping device (22) for generating vibrations of the clamping device (22) with the gear-shaped workpiece (23) clamped thereon
Implementation Method 2
The oscillating movement of the gear-shaped workpiece is then preferably generated by exciting a vibration of the clamping portion of the rotating clamping device. This excitation is preferably resonant, so that the vibration is an eigenmode of the clamping device with the gear-shaped workpiece clamped thereon
Data Source
AI summary
A method of generating machining of a gear-shaped workpiece (23), in particular by continuous generating grinding, in which the gear-shaped workpiece rotates about a workpiece axis (C) while in generating mesh with a generating machining tool. During machining, the gear-shaped workpiece performs an oscillating movement which is superimposed on the rotation of the gear-shaped workpiece. Also disclosed are a clamping device (22) configured to perform the method, and a system comprising such a clamping device and a control device (50). Finally, a generating machining machine comprising a clamping device of the mentioned type is also disclosed.