US20160193648A1 - Method for chamfering and polishing toothed workpieces - Google Patents

Method for chamfering and polishing toothed workpieces Download PDF

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Publication number
US20160193648A1
US20160193648A1 US15/069,858 US201615069858A US2016193648A1 US 20160193648 A1 US20160193648 A1 US 20160193648A1 US 201615069858 A US201615069858 A US 201615069858A US 2016193648 A1 US2016193648 A1 US 2016193648A1
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Prior art keywords
workpiece
tooth
tool
tool set
toothed
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Abandoned
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US15/069,858
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English (en)
Inventor
Johan Thijssen
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Felsomat GmbH and Co KG
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Felsomat GmbH and Co KG
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Assigned to FELSOMAT GMBH & CO. KG reassignment FELSOMAT GMBH & CO. KG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: THIJSSEN, Johan
Publication of US20160193648A1 publication Critical patent/US20160193648A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21H—MAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS
    • B21H5/00—Making gear wheels, racks, spline shafts or worms
    • B21H5/02—Making gear wheels, racks, spline shafts or worms with cylindrical outline, e.g. by means of die rolls
    • B21H5/022—Finishing gear teeth with cylindrical outline, e.g. burnishing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23F—MAKING GEARS OR TOOTHED RACKS
    • B23F19/00—Finishing gear teeth by other tools than those used for manufacturing gear teeth
    • B23F19/10—Chamfering the end edges of gear teeth

Definitions

  • the invention relates to a method for processing a toothed workpiece, wherein the workpiece is clamped on a rotating workpiece spindle and a first and a second tool set engage in the workpiece, wherein at least at a first side of the workpiece a chamfering is carried out at tooth front edges and a smoothing of tooth flanks is carried out close to the tooth front edges.
  • toothed arrangements are cut into a workpiece using the teeth of a hob cutter, wherein the workpiece and the hob cutter are rotated with mutual engagement. Subsequently, a chamfering of the tooth front edges (tooth end edges) of the workpiece is generally carried out.
  • the chamfering may in principle be carried out by means of machining or also shaping.
  • a portion of a chamfering tool is pressed onto the tooth front edges of the workpiece so that the material of the workpiece is plastically deformed in a localized manner.
  • a secondary burr at the front face (end face) of a respective tooth of the workpiece (which is typically removed with a cutting tool) and a material protuberance on the tooth flank of the respective tooth.
  • This material protuberance may be eliminated without a second cut by means of smoothing by a portion of a smoothing tool pressing on the tooth flank and thus rolling back the material protuberance.
  • a tool portion for the chamfering is constructed in a wedge-like manner and typically engages laterally in a tooth gap of the workpiece.
  • a chamfering tool set comprises two toothed discs which roll on the workpiece and which engage in the workpiece from both front faces.
  • the active tool portion is in this instance in abutment at both sides with a tooth of the workpiece.
  • the inner angle of the wedge-like tool portion may not exceed approximately 50°.
  • the sum of the chamfer angles of the produced opposing chamfers of the two adjacent teeth is thereby limited to approximately 50° (measured in each case relative to the inclination of the tooth arrangement or the extent direction of the tooth flanks), divided, for example, over a 20° chamfer and a 30° chamfer.
  • a tool portion is introduced into the tooth gaps of a workpiece, wherein the edges of the tool portion are in abutment at both sides at a shallow angle, in most cases approximately 2-4°, with the tooth flanks of the two surrounding teeth of the workpiece.
  • a smoothing tool set may also be implemented by means of two toothed discs which roll on the workpiece.
  • the object of the invention is to provide a method for chamfering and smoothing toothed workpieces by means of which larger chamfer angles can readily be produced on the tooth front edges (tooth end edges) of the workpiece.
  • This object is achieved with a method of the type mentioned in the introduction, which is characterized in that the first tool set engages at the first side of the workpiece with a wedge-like tool portion laterally in the tooth gaps in the workpiece, wherein the tooth front edges are chamfered on front tooth flanks with respect to a running direction of the workpiece and a smoothing of the tooth flanks is carried out close to the tooth front edges on rear tooth flanks with respect to the running direction of the workpiece, and in that the second tool set engages at the first side of the workpiece with a wedge-like tool portion laterally in the tooth gaps in the workpiece, wherein a smoothing of the tooth flanks is carried out close to the tooth front edges on front tooth flanks with respect to a running direction of the workpiece and the tooth front edges are chamfered on rear tooth flanks with respect to the running direction of the workpiece.
  • the invention makes provision for different functions to be carried out using the two edges of a wedge-like tool portion which engages at a (front/end) face of a workpiece between two teeth of the workpiece: one edge produces the chamfering on a first adjacent tooth of the workpiece, and the other edge produces the smoothing on a second adjacent tooth of the workpiece. Since for the smoothing of the second tooth only a shallow abutment angle of typically 5° or less is required, for the chamfering of the first tooth an angle of 40° or more, or even 45° or more, is readily available, even when the sum of the angles on the wedge-like workpiece portion (internal angle) is limited to approximately 50° as a result of the mechanical force relationships and the geometric relationships.
  • the wedge-like tool portions of a tool set are typically formed by the teeth of one or two tool toothed discs which are rolled on the workpiece.
  • the toothed discs may in particular be constructed in the manner of a bevel gear.
  • the wedge-like tool portions process the workpiece in a shaping manner, in particular during the chamfering operation. It should further be noted that the wedge-like tool portions do not need to terminate in a tip, simply as long as sufficiently long abutment edges (adjoining faces) which taper towards each other are constructed for the abutment against the teeth of the workpiece.
  • both tool sets engage in the workpiece at the same time.
  • an intervention which alternates several times is also possible.
  • an additional workpiece processing operation for material removal (for instance, a grinding or another hard fine processing operation) follows the chamfering and smoothing operations according to the invention, as a result of the steeper chamfers in the context of the invention, it is in principle possible to provide a greater residual chamfering region on the workpiece.
  • the chamfering of the tooth front edges is carried out at an angle of at least 35°, preferably at least 40°, in a particularly preferred manner at least 45°, measured relative to an inclination of the tooth arrangement on the workpiece.
  • the large chamfer angle enables a comparatively large chamfer length to be kept also in case of subsequent material removal; problems of excess hardening during a subsequent thermal processing operation are minimized.
  • the inclination angle may also be 0°; the inclination then extends parallel with the rotation axis of the workpiece.
  • wedge-like tool portions according to the invention preferably have an internal angle of 55° or less, in a particularly preferred manner 50° or less, and more preferably 48° or less, but conversely also have an internal angle of preferably at least 40°, in a particularly preferred manner at least 45°.
  • a variant is also advantageous in which the smoothing is carried out at an angle of a maximum of 5°, preferably a maximum of 4°, measured relative to an inclination of the tooth arrangement on the workpiece.
  • a method variant is preferred which also makes provision at a second side of the workpiece for a chamfering to be carried out on tooth front edges and a smoothing of tooth flanks to be carried out close to the tooth front edges, for the first tool set to engage at the second side of the workpiece with a wedge-like tool portion laterally in the tooth gaps in the workpiece, wherein a smoothing of the tooth flanks is carried out close to the tooth front edges on front tooth flanks with respect to a running direction of the workpiece and the tooth front edges are chamfered on rear tooth flanks with respect to the running direction of the workpiece, and for the second tool set to engage at the second side of the workpiece with a wedge-like tool portion laterally in the tooth gaps in the workpiece, wherein the tooth front edges are chamfered on front tooth flanks with respect to a running direction of the workpiece and a smoothing of the tooth flanks is carried out close to the tooth front edges on rear tooth flanks with respect to the running direction of the workpiece.
  • This variant also provides the chamfering and smoothing processing operation according to the invention for the opposing front face of the workpiece.
  • the same tool set for the same tooth flank carries out the chamfering operation at one side and the smoothing operation at the other side so that the introduction of force on the workpiece and on the tool sets is homogenized.
  • This variant also provides the chamfering and smoothing processing operation according to the invention for the opposing front face of the workpiece.
  • the same tool set for the same tooth flank carries out the chamfering operation at both sides or the smoothing operation at both sides, whereby, in an individual case, torsion moments on the workpiece can be minimized.
  • both tool sets can also be constructed on a common universal tool (which typically comprises a toothed disc for each workpiece side which is intended to be processed), typically with one of the tool sets being produced over half of the periphery of the common universal tool; during the rolling of the universal tool on the workpiece, the first and the second tool set are then alternately active at the same fixed location of the periphery (with respect to the fixed workpiece spindle).
  • a common universal tool which typically comprises a toothed disc for each workpiece side which is intended to be processed
  • a further development of this variant is advantageous in which the first tool set and the second tool set engage at the same time in the workpiece facing each other. An introduction of force into the workpiece spindle on which the workpiece is retained can thereby be minimized.
  • the scope of the present invention also includes a processing station for chamfering and smoothing a toothed workpiece, having a workpiece spindle for the toothed workpiece, a first tool set and a second tool set, constructed to carry out the above method according to the invention.
  • a processing station for chamfering and smoothing a toothed workpiece having a workpiece spindle for the toothed workpiece, a first tool set and a second tool set, constructed to carry out the above method according to the invention.
  • FIG. 1 a is a schematic illustration of the tool engagement on a workpiece with chamfering in accordance with the prior art
  • FIG. 1 b is a schematic illustration of a tool engagement with a workpiece during a smoothing operation according to the prior art
  • FIG. 2 a is a schematic illustration of a tool engagement with a workpiece according to a first variant of the method according to the invention
  • FIG. 2 b is a schematic illustration of the resulting workpiece after the tool engagement of FIG. 2 a;
  • FIG. 3 is a schematic illustration of a tool engagement in a workpiece according to a second variant of the method according to the invention.
  • FIG. 4 is a schematic illustration of a processing station according to the invention for carrying out the method according to the invention, as a plan view of one side of the workpiece;
  • FIG. 5 is a schematic oblique view of a tool set for the invention.
  • FIG. 6 is a schematic illustration of a tool set in engagement with a workpiece, when looking at the toothed narrow side of the workpiece, according to the invention.
  • the tooth edges are chamfered in order to prevent excess hardening of the tooth edges during a subsequent thermal processing operation which could lead to material notching during use and in order to reduce the risk of injury resulting from sharp edges or burrs when handling the toothed wheels.
  • the chamfers can be produced both in a machining and in a shaping manner. Depending on the production method, the results (chamfer angle with respect to inclination angle, chamfer size, chamfer path, etcetera) are different. Shaping methods of the chamfering are considered in greater detail below.
  • the chamfering tool comprises two toothed discs which engage at both sides of the tooth arrangement of the workpiece in the tooth gaps of the workpiece.
  • the sum of the two chamfer angles is limited to approximately 50°.
  • FIG. 1 a shows the dual-sided engagement of wedge-like portions 3 a, 3 b of a set of chamfer tools in a tooth gap 2 of a workpiece 1 in accordance with the prior art, as a schematic view of the narrow side of a toothed-wheel-like workpiece.
  • the portions 3 a, 3 b of the set of chamfer tools produce chamfers on the workpiece 1 with the two abutment edges thereof.
  • the inner angle ⁇ of a wedge-like tool portion 3 a, 3 b is mechanically and geometrically limited to approximately 50°.
  • the workpiece 1 in the prior art is also smoothed, cf. FIG. 1 b.
  • the edges of the portions 6 a, 6 b are in abutment with a shallow angle ⁇ of approximately 4° against the tooth flanks 7 a, 7 b; in each case, both edges of each portion 6 a, 6 b of the set of smoothing tools are used for smoothing.
  • the invention makes provision, using the two abutment edges (adjoining faces) of a wedge-like tool portion, for chamfering in the direction towards a tooth flank and for smoothing in the direction towards the other tooth flank, as will be explained in greater detail below with reference to FIG. 2 a.
  • Large chamfer angles can thereby be produced on all the tooth front edges.
  • first tool set WS 1 (illustrated with dashed lines) and a second tool set WS 2 (illustrated with continuous lines) which are used at a first location of the workpiece 11 (illustrated with dashed lines) and at a second location of the workpiece 11 (illustrated with continuous lines).
  • the first and second location are located over the periphery of the workpiece 11 so far apart that the tool sets WS 1 , WS 2 do not mutually impede each other.
  • the processing operation at a first side S 1 of the workpiece 11 on the left in FIG. 2 a is first intended to be illustrated in greater detail.
  • the first tool set WS 1 comprises at the first side S 1 a large number of wedge-like tool portions 17 on a bevel gear. For simplification, only one of these wedge-like tool portions 17 which engages currently in a tooth gap 12 in the workpiece 11 is illustrated.
  • the workpiece 11 rotates in accordance with the running direction LR marked with an arrow.
  • the tooth gap 12 is delimited by a front tooth flank 13 of a tooth 14 on the workpiece 11 in the running direction LR and is further delimited by a rear tooth flank 15 of a tooth 16 on the workpiece 11 .
  • the wedge-like tool portion 17 has two abutment edges 18 , 19 which enclose an internal angle ⁇ of approximately 50°.
  • the abutment edge 18 produces in the region of the tooth front edge (tooth end edge) 20 on the front tooth flank 13 a chamfer.
  • the abutment edge 19 smooths the rear tooth flank 15 in a region close to the tooth front edge (tooth end edge) 21 , wherein the abutment edge 19 is in abutment with the rear tooth flank 15 at a shallow angle.
  • the second tool set WS 2 has wedge-like tool portions 22 on another bevel gear. For simplification, only one of these wedge-like tool portions 22 which engages currently in a tooth gap 23 in the workpiece 11 is again illustrated.
  • the tooth gaps 12 and 23 are illustrated here for better understanding directly one above the other, but in practice in most cases are located spaced apart from each other over a considerable portion of the periphery of the workpiece 11 , for instance over half of the periphery.
  • the tooth gap 23 is again delimited by means of a front tooth flank 13 and a rear tooth flank 15 with respect to the running direction LR.
  • the wedge-like tool portion 22 also has two abutment edges 24 , 25 which enclose an internal angle ⁇ of approximately 50°.
  • the abutment edge 25 produces a chamfer in the region of the tooth front edge 21 on the rear tooth flank 15 .
  • the abutment edge 24 smooths the front tooth flank 13 in a region close to the tooth front edge 20 , wherein the abutment edge 24 is in abutment with the front tooth flank 13 at a shallow angle.
  • angles ⁇ and ⁇ are measured between a tangent of the chamfer or the smoothed tooth flank portion relative to the inclination (angle of inclination) 10 of the tooth arrangement of the workpiece 11 or relative to the tangent of the unchanged tooth flank 13 , 15 (which as a result of the parallelism of the inclination 10 and the unchanged tooth flanks 13 , 15 leads to the same angles).
  • the first tool set WS 1 has at the second side S 2 a large number of wedge-like tool portions 26 on a bevel gear. For simplification, only one of these wedge-like tool portions 26 which engages currently in the tooth gap 12 in the workpiece 11 , is again illustrated.
  • the wedge-like tool portion 26 has two abutment edges 27 , 28 which enclose an internal angle ⁇ of approximately 50°.
  • the abutment edge 28 produces a chamfer in the region of the tooth front edge (tooth end edge) 30 at the rear tooth flank 15 .
  • the abutment edge 27 smooths the front tooth flank 13 in a region close to the tooth front edge (tooth end edge) 29 , wherein the abutment edge 27 is in abutment with the front tooth flank 13 at a shallow angle.
  • the second tool set WS 2 has at the second side S 2 a large number of wedge-like tool portions 31 on a bevel gear. For simplification, only one of these wedge-like tool portions 31 which engages currently in a tooth gap 23 in the workpiece 11 , is again illustrated.
  • the wedge-like tool portion 31 has two abutment edges 32 , 33 which enclose an internal angle ⁇ of approximately 50°.
  • the abutment edge 32 produces a chamfer in the region of the tooth front edge 29 on the front tooth flank 13 .
  • the abutment edge 33 smooths the rear tooth flank 15 in a region close to the tooth front edge 30 , wherein the abutment edge 33 is in abutment with the rear tooth flank 15 at a shallow angle.
  • FIG. 3 a modification of the variant of the method according to the invention illustrated in FIG. 2 a, 2 b is set out.
  • the processing at the first side S 1 corresponds in this instance completely to the processing at the first side of the variant of FIG. 2 a, , 2 b.
  • the processing operation on the second side S 2 is set out in greater detail below.
  • the first tool set WS 1 has at the second side S 2 a large number of wedge-like tool portions 34 on a bevel gear. For simplification, only one of these wedge-like tool portions 34 which engages currently in the tooth gap 12 in the workpiece 11 is again illustrated.
  • the wedge-like tool portion 34 has two abutment edges 35 , 36 which enclose an internal angle ⁇ of approximately 50°.
  • the abutment edge 35 in this variant produces a chamfer in the region of the tooth front edge 29 on the front tooth flank 13 .
  • the abutment edge 36 smooths the rear tooth flank 15 in a region close to the tooth front edge 30 , wherein the abutment edge 36 is in abutment with the rear tooth flank 15 at a shallow angle.
  • the second tool set WS 2 has at the second side S 2 a large number of wedge-like tool portions 37 on a bevel gear. For simplification, only one of these wedge-like tool portions 37 which engages currently in the tooth gap 23 in the workpiece 11 is again illustrated.
  • the wedge-like tool portion 37 has two abutment edges 38 , 39 which enclose an internal angle ⁇ of approximately 50°.
  • the abutment edge 39 produces a chamfer in the region of the tooth front edge 30 on the rear tooth flank 15 .
  • the abutment edge 38 smooths the front tooth flank 13 in a region close to the tooth front edge 29 , wherein the abutment edge 38 is in abutment with the front tooth flank 13 at a shallow angle.
  • all the tooth front edges 29 , 30 of the workpiece 11 at the second side 2 are also chamfered at an angle ⁇ of approximately 45° and all the tooth flanks 13 , 15 are smoothed close to the tooth front edges 29 , 30 of the second side S 2 at an angle ⁇ of approximately 4°, in accordance with FIG. 2 b.
  • the first tool set WS 1 produces at both sides S 1 , S 2 the smoothing on the rear tooth flank 15 and the chamfers on the front tooth flank 13 .
  • the second tool set WS 2 produces at both sides S 1 , S 2 the smoothing on the front tooth flanks 13 and the chamfers on the rear tooth flanks 15 .
  • FIG. 4 is a schematic plan view of an embodiment of a processing station 40 according to the invention for carrying out the method according to the invention for combined chamfering and smoothing of a toothed workpiece 11 .
  • the toothed workpiece 11 which is arranged on a workpiece spindle 41 and which for the method is rotated in a motorized manner by means of the workpiece spindle 41 in the running direction LR, is in the embodiment shown in engagement with a first tool set WS 1 and a second tool set WS 2 which in this instance comprise toothed bevel gears (cf. FIG. 5 ).
  • the tool sets WS 1 , WS 2 are themselves rotatable (see arrow directions), typically freely rotatable or also rotatable in a motorized manner.
  • the two tool sets WS 1 , WS 2 roll on the workpiece 11 during the processing operation according to the invention of the workpiece 11 .
  • the tool sets WS 1 , WS 2 may be advanced in a substantially radial direction (in FIG. 4 upwards or downwards).
  • the tool sets WS 1 , WS 2 engage in the workpiece 11 at different locations on the periphery of the workpiece 11 , that is to say, at locations which are offset through 180° so that the workpiece 11 is arranged between them.
  • the tool sets WS 1 , WS 2 are toothed in such a manner that the teeth of the bevel gears of the tool sets WS 1 , WS 2 can each be used as wedge-like tool portions, by means of which a chamfering operation is carried out in the direction towards a first adjacent tooth of the workpiece 11 and a smoothing operation is carried out in the direction towards a second adjacent tooth (cf. in this regard, for example, FIG. 2 a ).
  • FIG. 5 is a schematic oblique view of the first tool set WS 1 of FIG. 4 .
  • the first tool set WS 1 comprises two mutually opposed bevel gears 51 , 52 which are rigidly connected to each other.
  • the second tool set WS 2 of FIG. 4 is constructed in a similar manner (not illustrated in greater detail).
  • the bevel gears 51 , 52 of the first tool set WS 1 of FIG. 5 engage with the teeth thereof, as illustrated in FIG. 6 , at the same time in the tooth arrangement of the workpiece 11 .
  • the teeth of the bevel gear 51 engage in this instance laterally in the tooth arrangement of the workpiece 11 ; the teeth of the bevel gear 51 are in this instance wedge-like tool portions 17 .
  • the teeth of the bevel gear 52 engage laterally in the tooth arrangement of the workpiece 11 ; the teeth of the bevel gear 52 are in this instance wedge-like tool portions 26 .
  • bevel gears of the second tool set WS 2 of FIG. 4 also engage in the workpiece 11 (not illustrated in greater detail).
US15/069,858 2013-09-16 2016-03-14 Method for chamfering and polishing toothed workpieces Abandoned US20160193648A1 (en)

Applications Claiming Priority (3)

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DE102013218542.1 2013-09-16
DE102013218542.1A DE102013218542B4 (de) 2013-09-16 2013-09-16 Verfahren zum Anfasen und Glätten von verzahnten Werkstücken und zugehörige Bearbeitungsstation
PCT/EP2014/069120 WO2015036373A2 (de) 2013-09-16 2014-09-09 Verfahren zum anfasen und glätten von verzahnten werkstücken

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PCT/EP2014/069120 Continuation WO2015036373A2 (de) 2013-09-16 2014-09-09 Verfahren zum anfasen und glätten von verzahnten werkstücken

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US (1) US20160193648A1 (zh)
EP (1) EP3046710B1 (zh)
CN (1) CN106061663B (zh)
DE (1) DE102013218542B4 (zh)
WO (1) WO2015036373A2 (zh)

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CN106061663A (zh) 2016-10-26
WO2015036373A2 (de) 2015-03-19
EP3046710A2 (de) 2016-07-27
DE102013218542B4 (de) 2015-09-24
EP3046710B1 (de) 2019-07-03
DE102013218542A1 (de) 2015-03-19
WO2015036373A3 (de) 2015-05-28
CN106061663B (zh) 2018-05-18

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