Wedge Tool Segmentation for Steep Gear Chamfers
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Solution Overview
Problem
Existing methods for chamfering and smoothing toothed workpieces are limited by small bevel angles, which lead to material loss during further machining and increased risk of overhardening and fractures during heat treatment.
Innovation Solution
A method using two sets of wedge-shaped tool sections on bevel gears that engage at different locations on the workpiece circumference, allowing for larger chamfer angles and simultaneous chamfering and smoothing functions, with one edge of each tool section performing chamfering and the other smoothing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If small bevel angles are used in conventional chamfering, then the internal angle of the wedge-shaped tool section remains within mechanical limits (approx. 50°), but the chamfer angle is limited and material loss occurs during further machining
Solution Approach 1:
The tool is divided into two separate tool sets (first and second tool sets), each with wedge-shaped tool sections that have different orientations. The first tool set creates a first bevel with a first bevel angle, while the second tool set creates a second bevel with a second bevel angle. This segmentation allows each tool set to operate independently with optimized angles, achieving a total chamfer angle that exceeds the conventional 50° limitation while minimizing material loss.
2Reliability
If small bevel angles are used, then the wedge-shaped tool section can be mechanically implemented, but the protection against overhardening during heat treatment is impaired and material fractures occur more easily
Solution Approach 1:
By using two separate tool sets with different bevel angles, the invention creates a chamfer that provides adequate protection against overhardening during heat treatment. The first tool set creates a bevel that protects the tooth edge, while the second tool set adds an additional bevel that enhances protection and reduces the risk of material fractures, thereby improving both reliability and strength.
3Productivity
If two separate tools are used for chamfering and smoothing as in prior art, then each tool performs its task completely alone, but the process requires more time and the tools are less efficient
Solution Approach 1:
The invention merges the functions of two separate tools into a single integrated tool structure. The first and second tool sets are mounted on the same tool holder and engage the workpiece simultaneously at different locations on the circumference. This allows chamfering and smoothing operations to be performed in one pass, significantly improving productivity and reducing process time compared to using separate tools that operate independently.
Solution Approach 2:
The tool holder is designed to accommodate multiple tool sets with different functions. The first tool set performs chamfering while the second tool set performs smoothing, and both operations are executed simultaneously on the same workpiece. This multi-functionality eliminates the need for separate machining operations, reducing cycle time and increasing overall machining efficiency.
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
Enables the creation of steeper chamfer angles, reducing material loss during subsequent machining and minimizing the risk of overhardening, while maintaining a limited internal angle of the wedge-shaped tool sections.
Implementation Method 1
a section of a chamfering tool is pressed against the front tooth edges of the workpiece, so that the material of the workpiece undergoes local plastic deformation
Data Source
Figure 1a~1b
Figure 2a
Figure 2b
AI summary
A method for processing a toothed workpiece (11), the workpiece (11) being clamped on a rotating workpiece spindle (41) and a first tool set (WS1) and a second tool set (WS2) engaging in the workpiece (11), wherein, at least on a first side (S1) of the workpiece (11), tooth end edges (20, 21, 29, 30) are chamfered and tooth flanks (13, 15) are polished close to the tooth end edges (20, 21, 29, 30), is characterized in that a wedge-shaped tool section (17) of the first tool set (WS1) engages laterally in the tooth gaps (12) on the workpiece (11) on the first side (S1) of the workpiece (11), the tooth end edges (20) being chamfered at front tooth flanks (13) relative to a running direction (LR) of the workpiece (11), and the tooth flanks (15) being polished close to the tooth end edges (21) at rear tooth flanks (15) relative to the running direction (LR) of the workpiece (11), and in that a wedge-shaped tool section (22) of the second tool set (WS2) engages laterally in the tooth gaps (23) on the workpiece (11) on the first side (S1) of the workpiece (11), the tooth flanks (13) being polished close to the tooth end edges (20) at front tooth flanks (13) relative to a running direction (LR) of the workpiece (11) and the tooth end edges (21) being chamfered at rear tooth flanks (15) relative to the running direction (LR) of the workpiece (11). The invention provides a method for chamfering and polishing toothed workpieces with which larger chamfer angles can easily be provided at the tooth end edges of the workpiece.